AUDI A4 1998 B5 / 1.G 01W Transmission Pinion Shaft Ring Gear Adjustment Owner's Manual

39-45


Measurement in following example "e" = 0.26 mm (red scale)
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.
Determining thickness of shim "S3"
Notes: - Turn mandrel until dial indicator plunger tip touches end gauge on
pinion shaft head, measure maximum runout (return point).
Formula:
S3
=
S3* + r + e
(-e- in black scale)
or
S3
=
S3* + r - e
(-e- in red scale)
The deviation "r" (tolerance) related to the VW385/30 master gauge
"Ro" is measured for the final drive sets supplied as replacement parts
and marked on the outer circumference of the ring gear. If measurements are based on red scale, subtract value "e."If measurements are based on black scale, add value "e."
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39-46

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
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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39-47

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)
0.49 0.69 0.85
0.57 0.73 0.89
0.61 0.77
0.65 0.81
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1) Using shim tolerances it is possible to find the
exact shim thickness required: insert two shims if
necessary.
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39-48

Checking measurement

Checking dimension "r"

- Install pinion shaft together with measured
shims S3 and S4 and turn 5 rotations in both
directions.

Note:
After removing universal mandrel, and with VW385/30 master gauge or
VW385/15 extension pin in place, check dial indicator again to see if it
indicates 0 with 2 mm preload. If not, correct adjustments. - Install universal mandrel Page 39
-43
, Determining dimension "e";
and perform check measurement.
- Read dial indicator counterclockwise (red scale).

If shims have been determined correctly, deviation "r" (as marked
on outer circumference of ring gear) should be indicated on dial
within a tolerance of 0.04 mm.
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39-49

Re-determining "S4" after replacing
transmission cover


Special tools and equipment

VW387 dial gauge holder
VW792/1 assembly tool
Dial indicator
Dial indicator extension
Depth gauge with minimum 5/100 mm
precision

- Clean housing mating surfaces.

Example: - Measure difference in depth "a" on old and new transmission cover.
Depth -a- (old transmission cover) 257.40 mm
Depth -a- (new transmission cover) 257.55 mm
= Difference 0.15 mm
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39-50

- Install thicker shim "S4" if new transmission
cover is deeper.

- Install thinner shim "S4" when the old
transmission cover is deeper.

Example:

Previous shim "S4" 0.95 mm
+ Difference 0.15 mm
= New shim "S4" 1.10 mm
Available shims Page 39
-47
, table

- Install tapered roller bearing outer race with
shim "S4" 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).
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39-51

Preload for tapered roller bearing for pinion
shaft, checking

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

Note:
The pinion shaft can be turned by simultaneously
turning both drive flanges.

- Install measuring tools and secure to transmission housing with bolt
(arrow).
- Attach dial indicator (3 mm 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, the dial indicator will now indicate
the following value: 0.05-0.15 mm.
- Remove measuring tools.
- Coat sealing surfaces with thin layer of sealant AMV 188 001 02.
- Tighten transmission cover bolts to 22 Nm (16 ft lb).
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39-52

Ring gear, adjusting


Adjusting differential
For a list of the repairs which will require the ring
gear to be adjusted Page 39
-33
, List of
adjustments

Special tools and equipment

VW382/10 dial indicator extension
VW385/17 magnetic plate
VW387 dial gauge holder
VW388 measuring lever
VW402 thrust plate
VW408A punch
VW472/1 pressure piece
VW521 adjustment tool
3177 clamp
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Torque gauge 0-600 Ncm
Dial indicator
Dial indicator extension 30 mm
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