AUDI A4 1999 B5 / 1.G 01W Transmission Pinion Shaft Ring Gear Adjustment User Guide

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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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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39-40

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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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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opposite dial indicator.
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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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