AUDI S4 1995 B5 / 1.G 01E Transmission Final Drive Pinion And Ring Gear Adjustment Owner's Guide

adjustment checked Page 39
-154
.
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39-169

Adjusting backlash
(Positioning ring gear in final drive housing)

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

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

- Turn differential 5 turns in both directions to
settle tapered roller bearings.

- Assemble measuring equipment.
Use dial gauge extension VW 382/10 (6 mm flat).
- Set measuring lever VW 388 to dimension "a" = 60 mm.
- Determine play between 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 1 mm preload.
Pa
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g
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39-170

- Turn ring gear back until lying against an
opposite tooth flank (backlash).

- Read backlash and note value.

-
Turn ring gear through 90 and repeat
measurements a further 3 times.
Note:
If the individual measurements differ by more
than 0.06 mm from each other, the installation of
the ring gear or the final drive set itself is not
correct. Check installation, replace final drive set
if necessary.

Determining average backlash

Example:

1st measurement 0.28 mm
+ 2nd measurement 0.30 mm
+ 3rd measurement 0.30 mm
+ 4th measurement 0.28 mm
= Sum of measured values 1.16 mm

Result: The average backlash is 1.16 4 =
0.29 mm
Pa
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justin
g
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39-171

Determining thickness of shim "S2"

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

Example:

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

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

Parts catalog
The following shims are available for "S2"

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

1) Using the shim tolerance variations it is
Pa
ge 34 of 38 Drive
pinion and rin
g gear, ad
justin
g
11/19/2002 htt
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yp
e=re
pair&id=AUDI.B5.TM03.39.19

possible to find 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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yp
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39-172

Determining thickness of shim "S1"

Formula:
"S1"
=
"S
total
" - "S2"

Example:

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

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

Parts catalog

The following shims are available for "S1"

Shim thickness (mm)
1)
0.15 0.50 0.90
0.20 0.60 1.00
0.30 0.70 1.20
Pa
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g gear, ad
justin
g
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yp
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0.40 0.80

1) Using the shim tolerance variations it is
possible to find the exact shim thickness
required, insert two shims if necessary.
Pa
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g gear, ad
justin
g
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39-173


Performing check measurement
Note:
Drive pinion with shim "S3" installed Differential with shims "S1" + "S2" installed
- Turn differential 5 turns in both directions so that 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 unchanged.
The individual measurements must not differ by more than 0.06 mm
from each other.
Pa
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pinion and rin
g gear, ad
justin
g
11/19/2002 htt
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yp
e=re
pair&id=AUDI.B5.TM03.39.19