transmission AUDI A4 1998 B5 / 1.G 01A Transmission Total Shim Thickness Workshop Manual

39-42


- Install double tapered roller bearing outer race for pinion shaft in
transmission housing without shims Fig. 3, Page 35
-31
.

Notes: - Install tapered roller bearing outer race for pinion shaft in transmission
cover together with shim S4* (1.0 mm thick) Fig. 8, Page 35
-33
.
A shim S4 with a thickness of 1.0 mm is installed for initial
measurement. It is referred in the following text as S4*. After
determining measurement "e", S4* is replaced with the appropriate
shim S4. When taking measurements, always install the rubber washer together
with the pressure plate for the rubber washer Page 35
-29
.
- Install fully assembled pinion shaft with hollow shaft into transmission
housing.
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39-43

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

- Turn transmission so transmission cover faces
downward.

- Press down on face of pinion shaft using VW296 removal tool until
tapered roller bearing outer race contacts transmission cover.
- While still maintaining pressure, rotate pinion shaft 5 turns in each
direction opposite hollow shaft to settle double tapered roller bearing.
- Rotate pinion shaft together with hollow shaft 5 turns in each direction
to settle tapered roller bearing.

Note:
The dial indicator extension must contact the machined surface on the
face of the pinion shaft. - Assemble measuring equipment, use 30 mm dial indicator extension.
- Set dial indicator (3 mm measuring range) to "0" with 1 mm preload.
-
Turn transmission 180 so transmission cover faces upward.
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39-45

Determining thickness of shim S3*

Formula:
S3*
=
Stotal - S4*

Example:


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

- Remove double tapered roller bearing outer
race, install shim S3* in transmission housing
and re-install outer race Fig. 3, Page 35
-31
.

- Insert fully assembled pinion shaft into
transmission housing again.

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

-
Rotate pinion shaft together with hollow shaft 5
turns in each direction, then rotate pinion shaft
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39-46


- Install measuring tools and secure to transmission housing using bolt
(arrow).
- Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft several times.
- If correct shims have been selected, dial indicator will now indicate the
following value:
0.05-0.15 mm
- Tighten transmission cover bolts again to 22 Nm (16 ft lb).
- Remove measuring tools.
- 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.
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39-48


Note:
Make sure gauge contact surface is precisely installed and free of oil. - Place end gauge on face of pinion shaft.

- Remove master gauge and install measuring mandrel into transmission
housing.
Dial indicator extension -A- = 6.5 mm long must be installed. The VW385/3 centering disc faces cover for final drive
- Install differential cover and tighten 4 bolts to 22 Nm (16 ft lb).
- Using adjustable ring, pull 2nd VW385/3 centering disc out as far as
possible, so mandrel can only just be turned by hand.
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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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39-58

Determining total shim thickness "Stotal" (S1
+ S2)
Adjusting preload of tapered roller bearings for
differential

Pinion shaft removed

Note:
If only the tapered roller bearings for the
differential are being replaced, the ring gear can
be removed from the differential housing. The
pinion shaft does not have to be removed.

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

- Remove shims Page 39
-21
.

Note:
For measurement purposes, a shim S2 of 1.20 mm is initially inserted and
referred to as S2* in the following text. After determining backlash, S2* will
be replaced by the correct shim S2. - Press right tapered roller bearing outer race with shim S2 into
transmission housing Fig. 2, Page 39
-27
. Shim S2* with thickness
of 1.20 mm (two 0.60 mm shims) is used for initial measurement.
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39-59


- Press tapered roller bearing outer race into differential cover without
shim S1 Fig. 8, Page 39
-31
.
- Insert differential without speedometer gear drive into transmission
housing. Ring gear is positioned on left-hand side infront of final drive
cover.
- Install differential cover with 4 bolts and tighten to 25 Nm (18 ft lb).
- Position transmission so differential cover faces upward.
- Turn differential 5 turns in both directions so tapered roller bearings
settle.

Note:
The tip of the dial indicator must be positioned on the center of the
differential. - Assemble measuring equipment, using 30 mm dial indicator extension.
- Set dial indicator (3 mm measuring range) -A- to "0" with 2 mm
preload.
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