Page 17 of 34
39-54
Transmission cover, replacing (re-
calculating shim S4
Special tools and equipment
VW385/3 centering disc (2x)
VW385/17 magnetic plate
VW387 dial indicator holder
VW792 installation arbor
Dial indicator
Dial indicator extension
Depth gauge with minimum 5/100 mm
precision
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11/20/2002 htt
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pair&id=AUDI.B5.TM02.39.7
Page 18 of 34
39-55
- Clean housing mating surfaces.
Example:
Example:
Available shims table, Page 39
-51
. - Measure difference in depth -a- on old and new transmission covers.
Depth "a" (old transmission cover) 257.40 mm
Depth "a" (new transmission cover) 257.55 mm
= Difference 0.15 mm
- Install thicker shim S4 if new transmission cover is deeper.
- Install thinner shim S4 if old transmission cover is deeper.
Previous shim S4 0.95 mm
+ Difference 0.15 mm
= New shim S4 1.10 mm
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Page 19 of 34
39-56
- Press tapered roller bearing outer race with shim
S4 into transmission cover Fig. 8, Page 35
-
33
.
- Reinsert assembled pinion shaft into
transmission housing fully.
- Install transmission cover and tighten bolts to 22
Nm (16 ft lb).
- To settle tapered roller bearings, rotate pinion
shaft together with hollow shaft 5 turns in each
direction, then rotate pinion shaft separately in
relation to hollow shaft 5 turns in each direction.
If correct shims have been selected, dial indicator will now indicate
following value:
0.05-0.15 mm
If this reading is not obtained the adjustment must be corrected. - Install measuring tools and secure with bolt (arrow) to transmission
housing.
- Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft several times.
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11/20/2002 htt
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play?action=Goto&t
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pair&id=AUDI.B5.TM02.39.7
Page 20 of 34
39-57
Ring gear, adjusting
Adjusting differential
For a list of the repairs which will require the ring
gear to be adjusted table, Page 39
-37
.
Special tools and equipment
VW382/10 extension pin
VW385/17 magnetic plate
VW386A clamping piece
VW387 dial indicator holder
VW388 measuring lever
VW402 thrust plate
VW408A punch
VW472/1 pressure piece
VW521 adjustment tool
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11/20/2002 htt
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yp
e=re
pair&id=AUDI.B5.TM02.39.7
Page 21 of 34
Torque gauge 0-600 Ncm (53 in. lb)
Dial indicator
Dial indicator extension
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Page 22 of 34
39-58
Determining total shim thickness "Stotal" (S1
+ S2)
Adjusting preload of tapered roller bearings for
differential
Pinion shaft removed
Note:
If only the tapered roller bearings for the
differential are being replaced, the ring gear can
be removed from the differential housing. The
pinion shaft does not have to be removed.
- Remove seals and outer races of both tapered
roller bearings for differential.
- Remove shims Page 39
-21
.
Note:
For measurement purposes, a shim S2 of 1.20 mm is initially inserted and
referred to as S2* in the following text. After determining backlash, S2* will
be replaced by the correct shim S2. - Press right tapered roller bearing outer race with shim S2 into
transmission housing Fig. 2, Page 39
-27
. Shim S2* with thickness
of 1.20 mm (two 0.60 mm shims) is used for initial measurement.
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ge 22 of 34 Total shim thickness Stotal for shim S3 + S4, determinin
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11/20/2002 htt
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.7
Page 23 of 34
39-59
- Press tapered roller bearing outer race into differential cover without
shim S1 Fig. 8, Page 39
-31
.
- Insert differential without speedometer gear drive into transmission
housing. Ring gear is positioned on left-hand side infront of final drive
cover.
- Install differential cover with 4 bolts and tighten to 25 Nm (18 ft lb).
- Position transmission so differential cover faces upward.
- Turn differential 5 turns in both directions so tapered roller bearings
settle.
Note:
The tip of the dial indicator must be positioned on the center of the
differential. - Assemble measuring equipment, using 30 mm dial indicator extension.
- Set dial indicator (3 mm measuring range) -A- to "0" with 2 mm
preload.
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11/20/2002 htt
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Page 24 of 34
39-60
- Lift differential without turning, and read off play
on dial indicator.
Measurement in following example: 0.62 mm
Notes:
To lift the differential, attach VW521/4 locking sleeve and VW521/12
on the right of the differential (housing side). If the measurement has to be repeated, the pinion shaft with hollow
shaft must be turned 5 turns in each direction first to settle the tapered
roller bearing.
Formula:
Stotal
=
S2*- + measurement + bearing preload
Example
Inserted shim(s) S2* 1.20 mm
+ Measured value 0.62 mm
+ Bearing preload (constant value) 0.30 mm
= Total thickness Stotal for S1 + S2 2.12 mm
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11/20/2002 htt
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pair&id=AUDI.B5.TM02.39.7
