AUDI S4 2000 B5 / 1.G 01E Transmission Final Drive Ring Gear Adjustment Workshop Manual

39-52


Ring gear, adjusting
(Adjusting differential)
Repairs after which the ring gear must be
adjusted Page 39
-37
.

Special tools, testers and auxiliary items

Drift VW 295
Dial gauge extension VW 382/10
Measuring plate VW 385/17
Universal dial gauge bracket VW 387
Measuring lever VW 388
Press plate VW 402
Installing tool VW 459/2
Ring gear adjusting device VW 521/4
Attachment for adjusting device VW 521/8
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39-53

Thrust pad 3062
Thrust plate 30-205
Mandrel 30-505
Torque gauge 0-600 Ncm
Dial gauge
Dial gauge extension
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39-54

Determining total shim thickness "S
total
" for
shims "S1" + "S2"
(Setting preload of tapered roller bearing for
differential)

Drive pinion removed

- Remove seal and outer races of both tapered
roller bearings for differential.

- Remove shims Page 39
-18
.

Note:
For measurement purposes a shim "S2" of 1.20 mm is initially inserted
which is designated "S2*" in the following. After determining backlash,
"S2*" will be replaced by the correct shim "S2." - Drive outer race for tapered roller bearing with shim "S2" into
transmission housing. For measurement purposes an "S2*" shim 1.20
mm thick (2 shims of 0.60 mm) is used.
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39-55


- Press outer race for tapered roller bearing without shim "S1" into cover
for differential.
- Insert differential without drive wheel for speedometer sender -G22 into
transmission housing. Ring gear is positioned on left-hand side (same
side as cover for final drive).
- Install cover for differential with 4 bolts (25 Nm).
- Position transmission so that cover for differential faces up.
- Turn differential 5 turns in both directions so that tapered roller
bearings settle.

Note:
The tip of the dial gauge must be positioned on center of differential. - Assemble measuring equipment, use a 30 mm dial gauge extension.
- Set dial gauge (3 mm measuring range) -A- to "0" with 2 mm preload.
- Lift differential, without turning, and read off play on dial gauge.
Measurement in following example: 0.62 mm.
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39-56

Note:

Secure special tools VW 521/4 and VW 521/8 on right of differential
(transmission side) to lift differential. If the measurement has to be repeated, the differential must again be
turned 5 turns in each direction to settle the tapered roller bearing.
Formula:
"Stotal
"
=
"S2*" + measurement + bearing preload
Example:

Inserted shim(s) "S2*" 1.20 mm
+ Measured value 0.62 mm
+ Bearing preload (constant) 0.25 mm
=
Total shim thickness "S
total
"
for "S1" + "S2"
2.07 mm
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39-57

Determining thickness of shim "S1*"

Note:

The preliminary adjustment shim "S1*" will be
replaced with the final shim "S1" after
determining the backlash.
The total shim thickness "S
total
" remains
unchanged.

Formula:
"S1*"
=
"S
total
" - "S2*"

Example:


Total shim thickness "S
total
"
for "S1" + "S2"
2.07 mm
- Inserted shim(s) "S2*" 1.20 mm
= Thickness of shim "S1*" 0.87 mm
Pa
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39-58

Measuring friction torque (check)

Note:

Differential tapered roller bearings are low
friction bearings. Therefore the friction torque
only has a limited use as a check. Correct
adjustment is only possible by determining the
total shim thickness "S
total
."

Do not additionally oil new tapered roller
bearings for friction torque measurement. The
bearings have already been treated with a
special oil by the manufacturer.
Drive pinion removed

Frictional torque specifications:
Note: - Fit torque gauge 0-600 Ncm -A- onto differential.
B - Socket
- Read off frictional torque. New bearings
Used bearings
200-350 Ncm 30-50 Ncm
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If the final drive set (drive pinion and ring gear) is being adjusted, perform
the adjustment of the drive pinion now and check the adjustment Page 39
-39
.
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39-59

Measuring backlash
(Position of ring gear in transmission housing)

Drive pinion with shims "S3" and "S4"
installed

- Install differential.

- Turn differential 5 turns in each direction to
settle tapered roller bearings.

- Secure dial gauge retainer VW 387 onto housing.
- Insert adjustment device VW 521/4 and VW 521/8 for ring gear.
- Fit dial gauge with dial gauge extension VW 382/10 (6 mm flat).
- Set measuring lever VW 388 to dimension a = 79 mm.
- Determine play between the teeth flanks as follows:
- Turn ring gear until it makes contact with a tooth flank (end of
backlash travel).
- Set dial gauge to "0" with 2 mm preload.
- Turn ring gear back until lying against an opposite tooth flank
(backlash).
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39-60

- Read off backlash and note value.

-
Turn ring gear through 90 and repeat
measurements a further 3 times.
Note:
If the individual measurements differ by more
than 0.06 mm from each other, the installation of
the ring gear or the final drive set itself is not
correct. Check installation, replace final drive set
if necessary.

Determining average backlash

- Add the four measurements together and divide
by four.

Example:

1st measurement 0.49 mm
+ 2nd measurement 0.48 mm
+ 3rd measurement 0.50 mm
+ 4th measurement 0.49 mm
= Sum of measured values 1.96 mm

Result: The average backlash is 1.96 4 =
0.49 mm
Pa
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