AUDI A4 1998 B5 / 1.G 01A Transmission Final Drive Gear Set User Guide

39-155


- Bolt on 3304 bracket with two hex-head bolts M8 x 30.
- Differential must be supported when tightening nut (e.g. using
VAG1359/2 universal mount and transmission hoist VAG1383A).
- Replace pinion shaft nut.
- Tighten pinion shaft nut, until no play can be felt on pinion shaft.
- Increase tightening torque until specified friction torque is attained,
measuring friction torque several times during this process.

1) Must have run at least 50 km (30 miles)
Note:
If the specified friction torque is exceeded, the spacer sleeve must be
replaced and the adjustment repeated. A spacer sleeve that has been
over-compressed at any time cannot be reused. A - Torque gauge, 0-600 Ncm (commercially available)
B - Socket extension, 36 mm
- Adjust friction torque as follows:
New bearings
Used bearings1)
200-250 Ncm (18-22 in. lb) 30-60 Ncm (3-5 in. lb)
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39-156


Dimension -a-: 60 mm (2.36 in.)
Dimension b: 55 mm (2.16 in.) - Set adjustment ring of VW385/1 universal mandrel.
- Set sliding adjustment ring.

VW385/15 dial indicator extension = 9 mm long
Ro = 57.50 mm (2.266 in.) - Assemble universal mandrel as illustrated:
- Set VW 385/30 master gauge-adjustable.
- Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
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39-157

Note:
Before carrying out following measurements turn
pinion shaft at least five turns in both directions,
so that the tapered roller bearings settle.
Otherwise a false reading will be obtained.

- Place VW 385/33 end dimension plate onto pinion shaft head.

- Remove master gauge-adjustable and insert measuring mandrel in
housing.
385/3 centering disc faces final drive cover
- Install final drive cover and tighten 4 bolts.
- By turning adjustable ring, move 2nd centering disc out until mandrel
can still just be turned by hand.
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39-158

Determining measurement "e"

Measurement in following example: e = 1.60 mm
Note:
Dimension "e" is required to determine thickness of shim S3.
Determining shim thickness "S3" - Turn mandrel until dial indicator point touches end measuring plate on
pinion shaft head, then measure maximum runout (return point).
Measured value is dimension"e"(red scale).
- After removing universal mandrel, and with VW385/30 master gauge-
adjustable in place, check once again whether dial indicator reads "0"
with 2 mm preload, otherwise repeat measurement.
Formula:
S3
=
e - r
e
=
Measured value
r
=
Deviation (tolerance): marked on ring gear in 1/100 mm
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39-159

Example:

Measured value e 1.60 mm
- Deviation r 0.42 mm
= Thickness of shim S3 1.18 mm

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

Shim thickness (mm)1)
0.95 1.20 1.45
1.00 1.25 1.50
1.05 1.30 1.55
1.10 1.35
1.15 1.40
1) By using the shim tolerance variations it is
possible to find the exact shim thickness required,
insert two shims if necessary.

- Remove universal mandrel.
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39-160

- Remove pinion shaft and large tapered roller
bearing outer race and install together with
measured shims S3 and spacer sleeve Page
39
-139
.

- Install small tapered roller bearing inner race
and tighten nut for pinion shaft until specified
friction torque is obtained Page 39
-144, Fig.
11
.

Notes:

Do not additionally oil new tapered roller
bearings for the friction torque measurement.
The bearings have already been treated with a
special oil by the manufacturer.
Increase tightening torque gradually and check
friction torque at regular intervals, if the
specified friction torque is exceeded, the spacer
sleeve must be replaced and the adjustment
repeated. A spacer sleeve that has been over-
compressed at any time cannot be reused.

- Adjust to following friction torques:

New bearings
Used bearings1)
200-250 Ncm (18-22 in.
lb) 30-60 Ncm (3-5 in.
lb)
Pa
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1) Must have run at least 50 km (30 miles)
Pa
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39-161

Checking measurements

Checking dimension "r"

- Turn pinion shaft at least 5 turns in both
directions.

If the shims have been correctly selected, the dial indicator should now
display the value of "r" as marked on the ring gear, reading
counterclockwise (red scale), within a tolerance of 0.04 mm. - Insert universal mandrel and carry out check measurement.

- Secure pinion shaft nut using mandrel.
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39-162

Ring gear, adjusting


Adjusting differential
The ring gear must be adjusted if any of the
components have been replaced table,
Page 39
-149
.

Notes:

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

Determining total shim thickness "Stotal" for
shims S1 + S2
(Setting preload of tapered roller bearing for
differential)
Pinion shaft removed or ring gear removed
from differential housing.

- Pry out drive flange seal using pry bar.
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- Remove differential tapered roller bearing outer
races and remove shims Page 39
-121
.
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