1997 AUDI A4 01A Transmission Final Drive Gear Set Workshop Manual

The marking "Oben" on 3253/4 thrust piece faces the nut of the puller.
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39-154


WARNING!
Wear protective gloves. - Install small tapered roller bearing outer race into housing.
- Lubricate outer race with oil and install using VW408A punch and 30-
205 thrust pad.
- Insert pinion shaft without spacer sleeve.

Notes: -
Heat tapered roller bearing inner race to approx. 100 C (212 F) and
install onto pinion shaft.
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. Install spacer sleeve only for final friction torque measurement (after
determining shim S3).
Pa
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39-155


- Bolt on 3304 bracket with two hex-head bolts M8 x 30.
- Differential must be supported when tightening nut (e.g. using
VAG1359/2 universal mount and transmission hoist VAG1383A).
- Replace pinion shaft nut.
- Tighten pinion shaft nut, until no play can be felt on pinion shaft.
- Increase tightening torque until specified friction torque is attained,
measuring friction torque several times during this process.

1) Must have run at least 50 km (30 miles)
Note:
If the specified friction torque is exceeded, the spacer sleeve must be
replaced and the adjustment repeated. A spacer sleeve that has been
over-compressed at any time cannot be reused. A - Torque gauge, 0-600 Ncm (commercially available)
B - Socket extension, 36 mm
- Adjust friction torque as follows:
New bearings
Used bearings1)
200-250 Ncm (18-22 in. lb) 30-60 Ncm (3-5 in. lb)
Pa
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39-156


Dimension -a-: 60 mm (2.36 in.)
Dimension b: 55 mm (2.16 in.) - Set adjustment ring of VW385/1 universal mandrel.
- Set sliding adjustment ring.

VW385/15 dial indicator extension = 9 mm long
Ro = 57.50 mm (2.266 in.) - Assemble universal mandrel as illustrated:
- Set VW 385/30 master gauge-adjustable.
- Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
Pa
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39-157

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

- Place VW 385/33 end dimension plate onto pinion shaft head.

- Remove master gauge-adjustable and insert measuring mandrel in
housing.
385/3 centering disc faces final drive cover
- Install final drive cover and tighten 4 bolts.
- By turning adjustable ring, move 2nd centering disc out until mandrel
can still just be turned by hand.
Pa
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39-158

Determining measurement "e"

Measurement in following example: e = 1.60 mm
Note:
Dimension "e" is required to determine thickness of shim S3.
Determining shim thickness "S3" - Turn mandrel until dial indicator point touches end measuring plate on
pinion shaft head, then measure maximum runout (return point).
Measured value is dimension"e"(red scale).
- After removing universal mandrel, and with VW385/30 master gauge-
adjustable in place, check once again whether dial indicator reads "0"
with 2 mm preload, 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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39-159

Example:

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

- Determine shim(s) according to table. Part
numbers 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) By using the shim tolerance variations it is
possible to find the exact shim thickness required,
insert two shims if necessary.

- Remove universal mandrel.
Pa
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39-160

- Remove pinion shaft and large tapered roller
bearing outer race and install together with
measured shims S3 and spacer sleeve Page
39
-139
.

- Install small tapered roller bearing inner race
and tighten nut for pinion shaft until specified
friction torque is obtained Page 39
-144, Fig.
11
.

Notes:

Do not additionally oil new tapered roller
bearings for the friction torque measurement.
The bearings have already been treated with a
special oil by the manufacturer.
Increase tightening torque gradually 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 that has been over-
compressed at any time cannot be reused.

- Adjust to following friction torques:

New bearings
Used bearings1)
200-250 Ncm (18-22 in.
lb) 30-60 Ncm (3-5 in.
lb)
Pa
ge 16 of 31 Final drive
gear set, recommended se
quence for ad
justin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.18