1997 AUDI A4 01A Transmission Total Shim Thickness Workshop Manual

39-48


Note:
Make sure gauge contact surface is precisely installed and free of oil. - Place end gauge on face of pinion shaft.

- Remove master gauge and install measuring mandrel into transmission
housing.
Dial indicator extension -A- = 6.5 mm long must be installed. The VW385/3 centering disc faces cover for final drive
- Install differential cover and tighten 4 bolts to 22 Nm (16 ft lb).
- Using adjustable ring, pull 2nd VW385/3 centering disc out as far as
possible, so mandrel can only just be turned by hand.
Pa
ge 9 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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.TM02.39.7

39-49


Measurement in following example "e" = 0.26 mm (red scale)
Note:
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, otherwise correct adjustments.
Determining thickness of shim "S3"
Notes:
The deviation "r" (tolerance) related to the VW385/30 master gauge "Ro"
is measured for the final drive sets supplied as replacement parts and
marked on the outer circumference of the ring gear. - Turn mandrel until dial indicator plunger tip touches end gauge on
pinion shaft head, measure maximum runout (return point).
Formula:
S3
=
S3* + r + e
(-e- in black scale)
or
S3
=
S3* + r - e
(-e- in red scale)
Pa
ge 10 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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.TM02.39.7

39-50

- If measurements are based on red scale,
subtract value "e."

- If measurements are based on black scale, add
value "e."

Example:

Shim S3* installed 0.60
mm
+ Deviation r 0.38
mm
- Value measured for "e" ( in red
scale)
0.26
mm
=
Thickness of shim S3 0.72
mm

- Determine shim(s) according to table. Part
numbers parts catalog
The following shims are available for "S3"

Shim thickness (mm)1)
0.40 0.55 0.70
0.45 0.60 0.75
Pa
ge 11 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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.TM02.39.7

0.50 0.65
1) Using shim tolerances it is possible to find the
exact shim thickness required, insert two shims if
necessary.
Pa
ge 12 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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.TM02.39.7

39-51

Determining thickness of shim "S4"

Formula:
S4
=
Stotal - S3

Example:


Total shim thickness Stotal for S3 +
S4
1.60
mm
- Thickness of shim S3 0.72
mm
= Thickness of shim S4 0.88
mm

- Determine shim(s) according to table. Part
numbers parts catalog
Available shims for "S4"

Shim thickness (mm)1)
0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
Pa
ge 13 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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.TM02.39.7

1) Using shim tolerances it is possible to find the
exact shim thickness required, insert two shims if
necessary.
Pa
ge 14 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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.TM02.39.7

39-52

Checking measurement
Checking dimension "r"

- Install pinion shaft/hollow shaft with measured
shims S3 and S4.

- Turn hollow shaft against pinion shaft 5 turns in
both directions, so tapered roller bearing can
settle.

Note:
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, otherwise correct adjustments. - Insert universal mandrel determining measurement "e", Page 39
-
47
and perform check measurement.
- Read off dial indicator counterclockwise (red scale).
If the shims have been correctly selected, deviation "r" (marked on
outer circumference of ring gear) must be displayed - within a tolerance
of 0.04 mm
Pa
ge 15 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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.TM02.39.7

39-53

Measuring friction torque

Notes:

Pinion shaft/hollow shaft tapered roller bearings
are low friction bearings. Therefore the friction
torque has only a limited use as a check.
Correct adjustment is only possible by
determining the total shim thickness Stotal.
Do not additionally oil new tapered roller
bearings to perform the friction torque
measurement. These bearings have already
been treated with a special oil by the
manufacturer.

Friction torque specification: - Install torque gauge, 0-600 Ncm (53 in. lb) on pinion shaft.
- Read off friction torque.
New bearings
Used bearings
150-250 Ncm (13-22 in. lb) 30-60 Ncm (3-5 in. lb)
Pa
ge 16 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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.TM02.39.7