1997 AUDI A4 01V Transmission Drive Pinion And Ring Gear Adjust Workshop Manual

39-180


- Adjust adjustment ring of VW385/1 measuring bar.

Dimension a = 60 mm
- Adjust sliding adjustment ring.
Dimension b = 55 mm

- Assemble measuring bar as shown in illustration.

VW385/15 extension pin 9 mm
- Adjust VW385/30 master gauge-adjustable.
Ro = 57.50 mm
- Set dial indicator (3 mm measuring range) to 0 with 2 mm preload.
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39-181

Note:
Turn differential at least 5 rotations in each
direction to seat the tapered roller bearings.
Otherwise, measurement will result in false
readings.

- Position VW385/33 end gauge on drive pinion head.

- Remove master gauge and insert measuring mandrel into housing.

VW385/3 plastic piece faces final drive cover
- Install cover for final drive and tighten four bolts.
- Using adjustable ring, pull 2nd centering disc out far enough, so that
the mandrel can only just be turned by hand.
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39-182

Determining dimension "e"

Note:
Dimension "e" is required to determine thickness of S3 shim.
Determining thickness of shim "S3" - Turn measuring mandrel until dial indicator plunger tip touches end
gauge on pinion shaft head, and measure the maximum run-out (return
point). Measured value is dimension "e" (red numbered area).

Measured value in the following example: "e" = 1.60 mm
- 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. If not, repeat measurement.
Formula:
"S3"
=
"e" - "r"
e
=
determined value
r
=
deviation (indicated in 1/100 mm on ring gear)
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39-183

Example:

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

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

Parts-catalog
Available shims for S3

Adjustment 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 shim tolerances, it is possible to
determine the exact shim thickness required,
insert two shims if necessary

- Removing universal mandrel.
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39-184

- Remove drive pinion and large tapered roller
bearing outer race and install together with
determined adjustment shim "S3" and spacer
sleeve Page 39
-159
onward.

- Insert small tapered roller bearing inner race and
tighten nut for drive pinion until specified friction
torque is attained Fig. 11
, page 39
-164
.

Notes:

Do not grease new tapered roller bearings
additionally for friction torque measurement.
The bearings are already greased with a
special oil from the factory.
Increase torque slowly and measure friction
torque multiple times. If the specified friction
torque is surpassed, replace spacer sleeve and
repeat adjustment! Any spacer sleeve that has
been pressed together too far one time must be
replaced.

- Adjust friction torque to following values:
New bearings
Run-in bearings
1)
200 to 250 Ncm 30 to 60 Ncm

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1) have been run in at least 50 km
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39-185

Perform check measurement

Checking dimension "r"

- Rotate drive pinion at least 5 complete
revolutions in both directions.

- Insert universal mandrel and perform check measurement.

If adjustment shims were determined correctly, dial indicator must
indicate deviation "r" with a tolerance of 0.04 mm (reading
counterclockwise in red number display).

- Peen drive pinion nut using mandrel.
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39-186

Ring gear, adjusting

(Adjusting differential)
Procedures after which the ring gear must be
adjusted Adjustment overview page 39
-
170
.

Notes:

Tapered roller bearings for differential are low-
friction bearings. Therefore friction torque can
only be used for check measurement in a
limited way. A correct adjustment is only
possible by determining the total thickness
"Sges".
Do not grease new tapered roller bearings
additionally for friction torque measurement.
The bearings are already greased with a
special oil from the factory.

Total shim thickness "Stotal" for adjustment
shims "S1" + "S2", determining
(adjust preload of tapered roller bearing for
differential)
Drive pinion removed or ring gear detached
from differential housing
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