differential AUDI A6 1996 C5 / 2.G 01E Transmission Final Drive Ring Gear Adjustment Workshop Manual

39-52


Ring gear, adjusting
(Adjusting differential)
Repairs after which the ring gear must be
adjusted Page 39
-37
.

Special tools, testers and auxiliary items

Drift VW 295
Dial gauge extension VW 382/10
Measuring plate VW 385/17
Universal dial gauge bracket VW 387
Measuring lever VW 388
Press plate VW 402
Installing tool VW 459/2
Ring gear adjusting device VW 521/4
Attachment for adjusting device VW 521/8
Pa
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39-54

Determining total shim thickness "S
total
" for
shims "S1" + "S2"
(Setting preload of tapered roller bearing for
differential)

Drive pinion removed

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

- Remove shims Page 39
-18
.

Note:
For measurement purposes a shim "S2" of 1.20 mm is initially inserted
which is designated "S2*" in the following. After determining backlash,
"S2*" will be replaced by the correct shim "S2." - Drive outer race for tapered roller bearing with shim "S2" into
transmission housing. For measurement purposes an "S2*" shim 1.20
mm thick (2 shims of 0.60 mm) is used.
Pa
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39-55


- Press outer race for tapered roller bearing without shim "S1" into cover
for differential.
- Insert differential without drive wheel for speedometer sender -G22 into
transmission housing. Ring gear is positioned on left-hand side (same
side as cover for final drive).
- Install cover for differential with 4 bolts (25 Nm).
- Position transmission so that cover for differential faces up.
- Turn differential 5 turns in both directions so that tapered roller
bearings settle.

Note:
The tip of the dial gauge must be positioned on center of differential. - Assemble measuring equipment, use a 30 mm dial gauge extension.
- Set dial gauge (3 mm measuring range) -A- to "0" with 2 mm preload.
- Lift differential, without turning, and read off play on dial gauge.
Measurement in following example: 0.62 mm.
Pa
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39-56

Note:

Secure special tools VW 521/4 and VW 521/8 on right of differential
(transmission side) to lift differential. If the measurement has to be repeated, the differential must again be
turned 5 turns in each direction to settle the tapered roller bearing.
Formula:
"Stotal
"
=
"S2*" + measurement + bearing preload
Example:

Inserted shim(s) "S2*" 1.20 mm
+ Measured value 0.62 mm
+ Bearing preload (constant) 0.25 mm
=
Total shim thickness "S
total
"
for "S1" + "S2"
2.07 mm
Pa
ge 5 of 15 Rin
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justin
g
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39-58

Measuring friction torque (check)

Note:

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 "S
total
."

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

Frictional torque specifications:
Note: - Fit torque gauge 0-600 Ncm -A- onto differential.
B - Socket
- Read off frictional torque. New bearings
Used bearings
200-350 Ncm 30-50 Ncm
Pa
ge 7 of 15 Rin
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justin
g
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39-59

Measuring backlash
(Position of ring gear in transmission housing)

Drive pinion with shims "S3" and "S4"
installed

- Install differential.

- Turn differential 5 turns in each direction to
settle tapered roller bearings.

- Secure dial gauge retainer VW 387 onto housing.
- Insert adjustment device VW 521/4 and VW 521/8 for ring gear.
- Fit dial gauge with dial gauge extension VW 382/10 (6 mm flat).
- Set measuring lever VW 388 to dimension a = 79 mm.
- Determine play between the teeth flanks as follows:
- Turn ring gear until it makes contact with a tooth flank (end of
backlash travel).
- Set dial gauge to "0" with 2 mm preload.
- Turn ring gear back until lying against an opposite tooth flank
(backlash).
Pa
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g gear, ad
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g
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39-63


Performing check measurement
Note: - After installing shims "S1" and "S2," turn differential 5 turns in both
directions so that the tapered roller bearings settle.
- Measure backlash four times on circumference.
Specifications: 0.12-0.22 mm
If the backlash lies outside the tolerances, the adjustments must be
repeated. But the total shim thickness "S
total
" must remain the same.
The individual measurements must not differ by more than 0.06 mm
from each other.
Pa
ge 15 of 15 Rin
g gear, ad
justin
g
11/19/2002 htt
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yp
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