AUDI A6 1999 C5 / 2.G 01E Transmission Final Drive Pinion And Ring Gear Adjustment User Guide

Universal support V.A.G 1359/2
Dial gauge extension 30 mm
Dial gauge
Torque gauge 0-600 Ncm
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39-154

Drive pinion, adjusting


Note:

Before adjusting drive pinion, adjust ring gear
(determine total shim thickness "S
total
" for
shims "S1" + "S2") Page 39
-163
.

The drive pinion only has to be readjusted if the
final drive set (ring gear and drive pinion), the
tapered roller bearings for the drive pinion or
the final drive housing are replaced. Adjustment
overview Page 39
-150
.

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.

Determine thickness of shim "S3"
(Setting preload of tapered roller bearings for
drive pinion)

- Mount final drive onto engine and transmission
support Page 39
-108
.

- Pull outer race of large tapered roller bearing into housing (without
shim).
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Note:
Inscription "Oben" with thrust washer 3253/4 faces the nut of the puller.
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39-155


- Pull outer race for small tapered roller bearing into housing.
- Lubricate outer race with oil and fit using press tool VW 408 A and
thrust plate 30-205.

CAUTION!
Wear protective gloves.
Note: - Insert drive pinion without spacer sleeve.
-
Heat inner race for tapered roller bearing to approx. 100 C and fit onto
drive pinion.
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. Only install spacer sleeve for final friction torque measurement (after
determining shim "S3").
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39-156


- Secure retainer 3304 with two M8 x 30 hex bolts.
- Support final drive when tightening nut (e.g. using universal support
V.A.G 1359/2 in conjunction with transmission jack V.A.G 1383 A).
- Fit a new drive pinion nut.
- Tighten drive pinion nut just far enough so that no play can be felt at
drive pinion.
- Gradually increase tightening torque, checking friction torque at regular
intervals, unti specified friction torque is obtained.

The following friction torques should be set: 1) run at least 50 km (30 miles) A - Torque gauge, commercially available, 0-600 Ncm
B - Extension with 32 mm socketNew bearings
Used bearings
1)
200-250 Ncm 30-60 Ncm
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39-157


- Set adjustment ring of universal mandrel VW 385/1.
Distance a = 60 mm
- Set sliding adjustment ring.
Dimension b = 55 mm

- Assemble universal mandrel as illustrated:
Dial gauge extension VW 385/15 = 9 mm long
- Set universal master gauge VW 385/30.
Ro = 57.50 mm
- Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
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39-158

Note:
Before performing following measurements turn
drive pinion at least five turns in both directions,
so that the tapered roller bearings settle.
Otherwise a false reading will be obtained.

- Place end measuring plate VW 385/33 onto drive pinion head.

- Remove master gauge and insert measuring mandrel in the housing.
The centering disc VW 385/3 faces toward cover for final drive
- Fit cover for final drive and tighten 4 bolts.
- Using adjustable ring, move 2nd centering disc out as far as possible
so that mandrel can still just be turned by hand.
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39-159

Determining measurement "e"

Note:
Dimension "e" is required to determine thickness of shim "S3."
Determining shim thickness "S3" - Turn mandrel until dial gauge point touches end measuring plate on
drive pinion head, then measure maximum deflection (return point).
Measured value is dimension "e" (in red scale).

Measurement in following example: "e" = 1.60 mm
- After removing universal mandrel, check once again whether dial
gauge reads "0" with 2 mm preload when master gauge VW 385/30 is
in place, otherwise repeat measurement.
Formula:
"S3"
=
"e" - "r"
e
=
Measured value
r
=
Deviation (tolerance): marked on ring gear in 1/100 mm
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39-160

Example:

Determined value "e" 1.60 mm
- Deviation "r" 0.42 mm
= Thickness of shim "S3" 1.18 mm

- Determine shim(s) as accurately as possible
from table.

Parts catalog
The following shims are available for "S3"

Shim thickness (mm)
1)
0.95 1.20 1.45
1.00 1.25 1.50
1.05 1.30 1.55
1.10 1.35
1.15 1.40

1) Using the shim tolerance variations it is
possible to find the exact shim thickness
required, insert two shims if necessary.

- Remove universal mandrel.
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39-161

- Remove drive pinion and outer race of large
tapered roller bearing and install together with
measured shims "S3" and spacer sleeve from
Page 39
-139
.
Install inner race of small tapered roller bearing
and tighten nut for drive pinion until specified
friction torque is obtained
Fig. 11 , Page 39
-144
.

Note:

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.
Increase tightening torque slowly and check
friction torque at regular intervals, if the
specified friction torque is exceeded, the spacer
sleeve must be replaced and the adjustment
repeated. A spacer sleeve which has been
compressed too much cannot be reused.

- Set to following friction torques:

New bearings
Used bearings
1)
200-250 Ncm 30-60 Ncm
Pa
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