AUDI A6 1999 C5 / 2.G 01V Transmission Drive Pinion And Ring Gear Adjust User Guide

39-175



30-205 thrust pad
2003/3 seal installer
2052/2 assembly tool for drive pinion
3005 thrust pad
3028 retainer
3062 thrust pad
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3253 wheel bearing assembly set with 3253/3
and 3253/4
3304 retainer
Engine/transmission jack VAG1383A
engine/gearbox jack
Dial gauge extension 30 mm
Dial gage
Torque gauge 0 - 600 Ncm
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Drive pinion, adjusting


Notes:

Before adjusting drive pinion, adjust ring gear
(determine total shim thickness "S" total" for
adjustment shims "S1" + "S2") page 39
-186
.

Drive pinion only has to be adjusted again if
gear set, tapered roller bearings for drive pinion
or final drive housing was replaced. Adjustment
overview page 39
-170
.

Do not grease new tapered roller bearings
additionally for friction torque measurement.
The bearings are already greased with a
special oil from the factory.

Determining Shim "S3"
(adjust preload of tapered roller bearing for drive
pinion)

- Clamp final drive into engine and transmission
assembly stand page 39
-123
.

Note: - Pull large tapered roller bearing outer race into housing.
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On 3253/4 pressure disc, marking "Oben" points toward nut on installation
device
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- Pulling small tapered roller bearing outer race into housing.
- The outer race must be oiled and installed using VW408A punch and
30-205 thrust pad.

WARNING!
Wear protective gloves!
Notes: - Install drive pinion without spacer sleeve.
-
Heat up small tapered roller bearing inner race to approx. 100 C and
position on drive pinion.
Do not grease new tapered roller bearings additionally for friction
torque measurement. The bearings are already greased with a special
oil from the factory. Only install spacer sleeve if friction torque has been adjusted (Shim
S3 already determined).
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- Install 3304 retainer using two hex bolts M8 x 30.
- When tightening nut, support final drive (e.g. using VAG1359/2
universal mount with VAG1383A transmission hoist).
- Always replace drive pinion nut.
- Tighten nut for drive pinion until no more drive pinion backlash is
present.
- Increase tightening torque further until specified friction torque is
attained; while tightening measure friction torque multiple times.

1) have been run in at least 50 km A - Standard torque gauge, 0 to 600 Ncm
B - Extension with 32 mm wrench socket
- Adjust to following friction torqueNew bearings
Run-in bearings
1)
200 to 250 Ncm 30 to 60 Ncm
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39-180


- Adjust adjustment ring of VW385/1 measuring bar.

Dimension a = 60 mm
- Adjust sliding adjustment ring.
Dimension b = 55 mm

- Assemble measuring bar as shown in illustration.

VW385/15 extension pin 9 mm
- Adjust VW385/30 master gauge-adjustable.
Ro = 57.50 mm
- Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.
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Note:
Turn differential at least 5 rotations in each
direction to seat the tapered roller bearings.
Otherwise, measurement will result in false
readings.

- Position VW385/33 end gauge on drive pinion head.

- Remove master gauge and insert measuring mandrel into housing.

VW385/3 plastic piece faces final drive cover
- Install cover for final drive and tighten four bolts.
- Using adjustable ring, pull 2nd centering disc out far enough, so that
the mandrel can only just be turned by hand.
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39-182

Determining dimension "e"

Note:
Dimension "e" is required to determine thickness of S3 shim.
Determining thickness of shim "S3" - Turn measuring mandrel until dial indicator plunger tip touches end
gauge on pinion shaft head, and measure the maximum run-out (return
point). Measured value is dimension "e" (red numbered area).

Measured value in the following example: "e" = 1.60 mm
- 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. If not, repeat measurement.
Formula:
"S3"
=
"e" - "r"
e
=
determined value
r
=
deviation (indicated in 1/100 mm on ring gear)
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Example:

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

- Determine shim as closely as possible according
to table. Part numbers

Parts-catalog
Available shims for S3

Adjustment 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) By using shim tolerances, it is possible to
determine the exact shim thickness required,
insert two shims if necessary

- Removing universal mandrel.
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