AUDI A4 1998 B5 / 1.G 01W Transmission Pinion Shaft Ring Gear Adjustment User Guide
Manufacturer: AUDI, Model Year: 1998, Model line: A4, Model: AUDI A4 1998 B5 / 1.GPages: 43, PDF Size: 0.59 MB
Page 11 of 43
39-36
VW519 sleeve
VW792 installation arbor
3005 thrust pad
Torque gauge 0-600 Ncm
Dial indicator
Dial indicator extension 9.3 mm
Dial indicator extension 6.5 mm
Dial indicator extension 30 mm
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Page 12 of 43
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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Page 13 of 43
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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Page 14 of 43
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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Page 15 of 43
39-40
Formula:
"Stotal"
=
"S4*" + measured value + bearing
preload
Example:
Installed shim "S4*" 1.00
mm
+ Dimension (example) 0.45
mm
+ Bearing preload (constant) 0.15
mm
=
Total shim thickness "Stotal" for "S3
+ S4"
1.60
mm
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Page 16 of 43
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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Page 17 of 43
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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Page 18 of 43
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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Page 19 of 43
opposite dial indicator.
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Page 20 of 43
39-44
Note:
Make sure gauge contact surface is precisely installed and free of oil. - Place end gauge on face of pinion shaft.
Note:
For transmissions with drive flange without polygon bearing ( Page 00
-
3 ) use VW385/2 centering disc instead of VW385/3 centering disc
opposite dial indicator. - Remove master gauge and install measuring mandrel into transmission
housing.
Dial indicator extension -A- = 6.5 mm long must be installed 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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yp
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