transmission AUDI A4 1996 B5 / 1.G 01W Transmission Pinion Shaft Ring Gear Adjustment Workshop Manual

39-32


Installation position of adjustment shims

Note:
List of adjustments when replacing individual
components of transmission Page 39
-33
.
S1 - Adjustment shim for ring gear in final
drive cover
S2 - Adjustment shim for ring gear in
transmission housing
S3 - Adjustment shim for pinion shaft in
transmission housing
S4 - Adjustment shim for pinion shaft in
transmission cover
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39-33
List of adjustments

Note:
If repairs have been carried out on the transmission, it is only necessary to adjust the pinion shaft, ring gear or gear set if
components have been replaced that directly influence the final drive adjustment. To avoid unnecessary adjustments, refer to
the following table:

Component to be adjusted:

Component replaced:

Ring gear
"S1"+ "S2" 1)

Page 39
-52

Pinion shaft
"S3"+ "S4" 1)
via deviation "r"
Page 39
-35

Pinion shaft
"S4" 1)

Page 39
-49

Backlash measurement

Page Page 39
-58

Transmission housing 3) X X X
Transmission cover X
Differential housing X X
Tapered roller bearing for pinion shaft X X
Tapered roller bearing for differential X X
Gear set 2)
X X X
Cover for final drive X X 1) Adjustment shims: installation position Page 39
-32
.
2) Replace pinion shaft and ring gear together as a set only.
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3) If the transmission housing is replaced, adjust input shaft Page 35
-17
.
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39-35

Pinion shaft, adjusting

Procedures, after which the pinion shaft must be
adjusted Page 39
-33
, table

Special tools and equipment

VW204B installation tool for crankshaft seal
VW296 removal tool
VW385 universal gauge
VW385/1 measuring bar
VW385/2 centering disc (for transmissions
without polygon bearing)
VW383/3 centering disc (2x)
VW385/14 measuring rod
VW385/15 extension pin
VW385/30 master gauge (adjustable)

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39-37

Determining total shim thickness Stotal for
shims S3 + S4

- Adjust preload of tapered roller bearing for
pinion shaft.

Differential removed

- Pressing on double tapered roller bearing inner
race Page 35
-21
.

Note:
The illustration shows the pinion shaft without gears. - Secure lower tapered roller bearing (arrow).

Pressure plates with a thickness of 14.8 mm or 15.3 mm can be installed. - Install tapered roller bearing outer race for pinion shaft without shims
into transmission housing Fig. 3, Page 35
-30
.
- Install rubber washer (item 40 , Page Page 35
-28
) and pressure
plate (item - 39 -, Page Page 35
-28
) into transmission cover.
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39-38


Note:
A shim S4 with a thickness of 1.0 mm is installed for initial measurement.
It is referred to in the following text as S4*. After determining
measurement "e," S4* is replaced with the appropriate shim S4. - Install tapered roller bearing outer race for pinion shaft with shim S4*
(1.0 mm thickness) into transmission cover Fig. 8, Page 35
-32
.
- Install fully assembled pinion shaft into transmission housing.
- Install transmission cover and tighten to 22 Nm (16 ft lb).
- Turn transmission so that the transmission cover points downward.

- Press down on face of pinion shaft using VW296 removal tool until
tapered roller bearing outer race contacts transmission cover.
- While maintaining pressure, turn pinion shaft by hand to seat tapered
roller bearing.
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39-39


Note:
Make sure dial indicator extension contacts machined surface on face of
drive shaft. - Assemble measuring equipment, use 30mm dial indicator extension.
- Set dial indicator (3 mm measuring range) to 0 with 1mm preload.
-
Turn transmission 180 , so transmission cover faces upward.- Turn pinion shaft 5 rotations in each direction to seat the tapered roller
bearing.

Note:
If the measurement has to be repeated, first turn pinion shaft 5 rotations in
both directions to seat the tapered roller bearing. Set dial indicator to 0
with 2mm preload. - Read play on dial indicator and note.
Dimension in the following example: 0.45 mm
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39-41

Determining thickness of shim "S3*"

Formula:
"S3*"
=
"Stotal" - "S4*"

Example:


Total shim thickness "Stotal" for "S3
+ S4"
1.60
mm
- Installed shim "S4*" 1.00
mm
= Thickness of shim "S3*" 0.60
mm

- Remove tapered roller bearing outer race, install
shim "S3*" into transmission housing and re-
install outer race Fig. 3, Page 35
-30
.

- Install fully assembled pinion shaft into
transmission housing.

- Install transmission cover and tighten to 22 Nm
(16 ft lb).
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39-42

Checking preload for tapered roller bearing
for pinion shaft

- Turn pinion shaft 5 rotations in each direction to
seat tapered roller bearing.

Notes:

If the pinion shaft cannot be turned by hand,
install a M10 x 20 bolt into face of pinion shaft
and turn the pinion shaft at this bolt using tool.
Remove bolt after turning pinion shaft.

- Install measuring tools and secure to transmission housing with bolt
(arrow).
- Attach dial indicator (3mm measuring range) to center of transmission
cover and set to 0 with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft.
If correct shims have been selected, dial indicator will now indicate the
following value: 0.05-0.15 mm.
- Tighten transmission cover bolts to 22 Nm (16 ft lb).
- Remove measuring tools.
- Turn pinion shaft 5 rotations in each direction to seat tapered roller
bearing.
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39-43

Calculating dimension "e"

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

- Set adjustment rings of universal mandrel using VW385/1 measuring
bar to the following measurements:

Dimension -a- = 35 mm
Dimension -b- = 75 mm

Note:
For transmissions with drive flange without polygon bearing ( Page 00
-
3 ) use VW385/2 centering disc instead of VW385/3 centering disc - Assemble VW385/1 measured bar as illustrated:Dial indicator extension A
Ro
Ring gear diameter
6.5 mm for VW385/30 master gauge 54.95 170 mm
9.3 mm for VW385/15 extension pin 59.65 180 mm - Set dial indicator (3 mm measuring range) to 0 with 2mm preload.
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