AUDI A4 1996 B5 / 1.G 01A Transmission Total Shim Thickness User Guide

39-50

- If measurements are based on red scale,
subtract value "e."

- If measurements are based on black scale, add
value "e."

Example:

Shim S3* installed 0.60
mm
+ Deviation r 0.38
mm
- Value measured for "e" ( in red
scale)
0.26
mm
=
Thickness of shim S3 0.72
mm

- Determine shim(s) according to table. Part
numbers parts catalog
The following shims are available for "S3"

Shim thickness (mm)1)
0.40 0.55 0.70
0.45 0.60 0.75
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0.50 0.65
1) Using shim tolerances it is possible to find the
exact shim thickness required, insert two shims if
necessary.
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39-51

Determining thickness of shim "S4"

Formula:
S4
=
Stotal - S3

Example:


Total shim thickness Stotal for S3 +
S4
1.60
mm
- Thickness of shim S3 0.72
mm
= Thickness of shim S4 0.88
mm

- Determine shim(s) according to table. Part
numbers parts catalog
Available shims for "S4"

Shim thickness (mm)1)
0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Pa
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g
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7

1) Using shim tolerances it is possible to find the
exact shim thickness required, insert two shims if
necessary.
Pa
ge 14 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
g
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yp
e=re
pair&id=AUDI.B5.TM02.39.7

39-52

Checking measurement
Checking dimension "r"

- Install pinion shaft/hollow shaft with measured
shims S3 and S4.

- Turn hollow shaft against pinion shaft 5 turns in
both directions, so tapered roller bearing can
settle.

Note:
After removing universal mandrel, and with VW385/30 master gauge in
place, check dial indicator again to see if it indicates "0" with 2 mm
preload, otherwise correct adjustments. - Insert universal mandrel determining measurement "e", Page 39
-
47
and perform check measurement.
- Read off dial indicator counterclockwise (red scale).
If the shims have been correctly selected, deviation "r" (marked on
outer circumference of ring gear) must be displayed - within a tolerance
of 0.04 mm
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39-53

Measuring friction torque

Notes:

Pinion shaft/hollow shaft tapered roller bearings
are low friction bearings. Therefore the friction
torque has only a limited use as a check.
Correct adjustment is only possible by
determining the total shim thickness Stotal.
Do not additionally oil new tapered roller
bearings to perform the friction torque
measurement. These bearings have already
been treated with a special oil by the
manufacturer.

Friction torque specification: - Install torque gauge, 0-600 Ncm (53 in. lb) on pinion shaft.
- Read off friction torque.
New bearings
Used bearings
150-250 Ncm (13-22 in. lb) 30-60 Ncm (3-5 in. lb)
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39-54

Transmission cover, replacing (re-
calculating shim S4


Special tools and equipment

VW385/3 centering disc (2x)
VW385/17 magnetic plate
VW387 dial indicator holder
VW792 installation arbor
Dial indicator
Dial indicator extension
Depth gauge with minimum 5/100 mm
precision
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39-55

- Clean housing mating surfaces.

Example:
Example:
Available shims table, Page 39
-51
. - Measure difference in depth -a- on old and new transmission covers.
Depth "a" (old transmission cover) 257.40 mm
Depth "a" (new transmission cover) 257.55 mm
= Difference 0.15 mm
- Install thicker shim S4 if new transmission cover is deeper.
- Install thinner shim S4 if old transmission cover is deeper.
Previous shim S4 0.95 mm
+ Difference 0.15 mm
= New shim S4 1.10 mm
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39-56

- Press tapered roller bearing outer race with shim
S4 into transmission cover Fig. 8, Page 35
-
33
.

- Reinsert assembled pinion shaft into
transmission housing fully.

- Install transmission cover and tighten bolts to 22
Nm (16 ft lb).

- To settle tapered roller bearings, rotate pinion
shaft together with hollow shaft 5 turns in each
direction, then rotate pinion shaft separately in
relation to hollow shaft 5 turns in each direction.

If correct shims have been selected, dial indicator will now indicate
following value:
0.05-0.15 mm
If this reading is not obtained the adjustment must be corrected. - Install measuring tools and secure with bolt (arrow) to transmission
housing.
- Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft several times.
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39-57

Ring gear, adjusting


Adjusting differential
For a list of the repairs which will require the ring
gear to be adjusted table, Page 39
-37
.

Special tools and equipment

VW382/10 extension pin
VW385/17 magnetic plate
VW386A clamping piece
VW387 dial indicator holder
VW388 measuring lever
VW402 thrust plate
VW408A punch
VW472/1 pressure piece
VW521 adjustment tool
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g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7