AUDI S4 1996 B5 / 1.G 01E Transmission Final Drive Pinion Adjustment Workshop Manual

39-39


Drive pinion, adjusting
(Adjusting drive pinion and hollow shaft)
Repairs after which the drive pinion must be
adjusted Page 39
-37
, table

Special tools, testers and auxiliary items

Universal mandrel VW 385/1
Centering disc VW 385/2
Centering disc VW 385/3
Measuring plunger VW 385/14
Measuring plate VW 385/17
Master gauge VW 385/30
Universal dial gauge bracket VW 387
Press tool VW 407
Multi-purpose tool VW 771/15
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Thrust pad 3062
Pin 3114/2
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39-40

Clamping sleeve 3116
Bolt 3116/1
Torque gauge 0-600 Ncm
Dial gauge
Dial gauge extension 6.5 mm
Dial gauge extension 30 mm
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39-41

Determining total shim thickness "S
total
" for
shims "S3" + "S4"
(Setting preload of tapered roller bearing for drive
pinion with hollow shaft)

Differential removed

- Clamp drive pinion in a vice using clamps -A-.
- Insert tapered rollers with grease, assemble drive pinion and hollow
shaft.
- Turn hollow shaft against drive pinion five turns in both directions so
that tapered roller bearings settle.
- Preload drive pinion/hollow shaft to 10 Nm, hold hollow shaft when
doing this.
- Insert outer race for tapered roller bearing for drive pinion into
transmission housing without shims Fig. 2 , Page 35
-22
and
Fig. 3 , Page 35
-23
.
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39-42


Note:
For measurement purposes a shim "S4" of 1.0 mm is initially inserted
which is designated "S4*" After determining measurement "e" "S4*" will be
replaced by the correct shim "S4." - Insert outer race for tapered roller bearing for drive pinion with shim
"S4*" (1.0 mm thick) into bearing plate.
- Insert completely assembled drive pinion in transmission housing.
- Fit bearing plate with dowel sleeves and tighten to 25 Nm.
- Turn drive pinion with hollow shaft five turns in both directions so that
tapered roller bearings settle.

Note:
The tip of the dial gauge must be positioned on center of drive pinion. - Assemble measuring equipment, use a 30 mm dial gauge extension.
- Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
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39-43

- Lift drive pinion, without turning, and read off
play on dial gauge.

Measurement in example: 0.90 mm

Note:
If the measurement has to be repeated, the drive
pinion with hollow shaft must be turned 5 turns in
each direction to settle the tapered roller
bearings. Set dial gauge again to "0" with 2 mm
preload.

Formula:
"S
total
"
=
"S4*" + measurement + bearing
preload

Example:

Inserted shim "S4*" 1.00
mm
+ Measured value (example) 0.90
mm
+ Bearing preload (constant) 0.15
mm
=
Total shim thickness "S
total
" for "S3"
+ "S4"
2.05
mm
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39-44

Determining thickness of shim "S3*"

Formula:
"S3*"
=
"S
total
" - "S4*"

Example:


Total shim thickness "S
total
" for "S3"
+ "S4"
2.05
mm
- Inserted shim "S4*" 1.00
mm
= Thickness of shim "S3*" 1.05
mm
Remove outer race for tapered roller bearing,
insert shim "S3*" into transmission housing and
install outer race again
Fig. 2 , Page 35
-22
and
Fig. 3 , Page 35
-23
.

- Insert completely assembled drive pinion into
transmission housing again.

- Fit bearing plate with dowel sleeves and tighten
securing bolts to 25 Nm.
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- Turn drive pinion with hollow shaft five turns in
both directions to settle the tapered roller
bearing.
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39-45

Determining measurement "e"

Note:
Measurement "e" is required to determine the
final shim thickness of "S3" and "S4."

- Set adjustment rings of universal mandrel VW 385/1 to the following
measurements:

Dimension a = 65 mm
Dimension b = 55 mm

- Assemble universal mandrel VW 385/1 as illustrated:

Dial gauge extension VW 385/15, 9.3 mm long
Master gauge VW 385/30
- Set master gauge VW 385/30 to Ro = 59.65 mm and fit onto mandrel.
- Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
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39-46

Note:
The gauge VW 385/27 can also be used in place
of the master gauge VW 385/30 (Ro = 59.65
mm).

Arrangement of measuring equipment when determining dimension "e"
Note:
Ensure plate contact surface fits exactly and is free of oil. - Place end measuring plate VW 385/17 onto drive pinion head.
- Take master gauge off mandrel.
- Insert mandrel into transmission housing.

The centering disc 385/3 faces toward cover for final drive
- Fit cover for final drive and tighten 4 bolts to 25 Nm.
- Using adjustable ring, pull 2nd centering disc VW 385/2 out as far as
possible so that mandrel can still just be turned by hand.
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