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

should now be checked page 39
-177
.
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39-192

Adjusting backlash
(position of ring gear in transmission housing)

Drive pinion installed with shim S3
Differential installed with shims "S1*" and
"S2*"

- Insert differential into final drive housing, install
cover and tighten all bolts to 25 Nm.

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

- Install measuring tools.
- Use VW382/10 extension pin, 6 mm.
- Set VW388 measuring lever to dimension "a" = 60 mm.
- Determine backlash between teeth flanks as follows:
- Turn ring gear until it contacts a tooth flank (end of backlash travel).
- Set dial indicator to 0 with 1 mm preload.
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g
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39-193

- Turn ring gear back until it contacts opposite
tooth flank (backlash).

- Read backlash and note.

-
Turn ring gear an additional 90 in each case
and repeat measurement 3 times.
Note:
If measurements vary more than 0.06 mm from
each other, ring gear or gear set is not installed
correctly. Check installation, replace gear set if
necessary.

Determining average backlash

Example:

1. Measurement 0.28 mm
+ 2. Measurement 0.30 mm
+ 3. Measurement 0.30 mm
+ 4. Measurement 0.28 mm
= Total of measurements 1.16 mm

Result: The average backlash is 1.16 mm / 4
= 0.29 mm
Pa
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g gear, ad
justin
g
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39-194

Determining thickness of shim "S2"

Formula:
"S2"
=
"S2*" - backlash + lift

Example:

Installed shim "S2*" 1.00 mm
- Average backlash 0.29 mm
+ Lift (constant) 0.15 mm
= Thickness of shim "S2" 0.86 mm

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

Parts-catalog
Available shims for S2

Adjustment shim thickness (mm)
1)
0.15 0.50 1.50
0.20 0.80
0.25 1.00

1) By using shim tolerances, it is possible to
Pa
ge 34 of 38 Drive
pinion and rin
g gear, ad
justin
g
11/20/2002 htt
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yp
e=re
pair&id=AUDI.B5.AT01.39.15

determine the exact shim thickness required,
insert two shims if necessary
Pa
ge 35 of 38 Drive
pinion and rin
g gear, ad
justin
g
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39-195

Determining thickness of shim "S1"

Formula:
"S1"
=
"Stotal" - "S2"

Example:

Total shim thickness "Stotal" for "S1"
+ "S2" 1.80
mm
- Thickness of shim "S2" 0.86
mm
= Thickness of shim "S1" 0.94
mm

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

Parts-catalog
Available shims for S1

Thickness of adjustment shims in mm
1)
0.15 0.50 0.90
0.20 0.60 1.00
0.30 0.70 1.20
Pa
ge 36 of 38 Drive
pinion and rin
g gear, ad
justin
g
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yp
e=re
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0.40 0.80

1) By using shim tolerances, it is possible to
determine the exact shim thickness required,
insert two shims if necessary
Pa
ge 37 of 38 Drive
pinion and rin
g gear, ad
justin
g
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39-196


Checking measurement
Notes:
Drive pinion installed with shim S3 Differential installed with shims "S1" and "S2"
- Turn differential 5 rotations in each direction to seat the tapered roller
bearing.
- Measure backlash 4 times on circumference.

Specification: 0.12 to 0.22 mm
If backlash is outside tolerance, repeat adjustments. Do not change
total shim thickness "Stotal" while doing so. The individual measurement values can deviate a maximum of 0.06
mm from each other
Pa
ge 38 of 38 Drive
pinion and rin
g gear, ad
justin
g
11/20/2002 htt
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yp
e=re
pair&id=AUDI.B5.AT01.39.15