1998 AUDI A4 01W Transmission Pinion Shaft Ring Gear Adjustment Workshop Manual

39-42

Checking preload for tapered roller bearing
for pinion shaft

- Turn pinion shaft 5 rotations in each direction to
seat tapered roller bearing.

Notes:

If the pinion shaft cannot be turned by hand,
install a M10 x 20 bolt into face of pinion shaft
and turn the pinion shaft at this bolt using tool.
Remove bolt after turning pinion shaft.

- Install measuring tools and secure to transmission housing with bolt
(arrow).
- Attach dial indicator (3mm measuring range) to center of transmission
cover and set to 0 with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft.
If correct shims have been selected, dial indicator will now indicate the
following value: 0.05-0.15 mm.
- Tighten transmission cover bolts to 22 Nm (16 ft lb).
- Remove measuring tools.
- Turn pinion shaft 5 rotations in each direction to seat tapered roller
bearing.
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39-43

Calculating dimension "e"

Note:
Dimension "e" is required to determine the final
shim thickness of S3 and S4.

- Set adjustment rings of universal mandrel using VW385/1 measuring
bar to the following measurements:

Dimension -a- = 35 mm
Dimension -b- = 75 mm

Note:
For transmissions with drive flange without polygon bearing ( Page 00
-
3 ) use VW385/2 centering disc instead of VW385/3 centering disc - Assemble VW385/1 measured bar as illustrated:Dial indicator extension A
Ro
Ring gear diameter
6.5 mm for VW385/30 master gauge 54.95 170 mm
9.3 mm for VW385/15 extension pin 59.65 180 mm - Set dial indicator (3 mm measuring range) to 0 with 2mm preload.
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opposite dial indicator.
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39-44


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

Note:
For transmissions with drive flange without polygon bearing ( Page 00
-
3 ) use VW385/2 centering disc instead of VW385/3 centering disc
opposite dial indicator. - Remove master gauge and install measuring mandrel into transmission
housing.
Dial indicator extension -A- = 6.5 mm long must be installed 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.
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39-45


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: - 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)
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. If measurements are based on red scale, subtract value "e."If measurements are based on black scale, add value "e."
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39-46

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
0.50 0.65
1) Using shim tolerances it is possible to find the
exact shim thickness required: insert two shims if
necessary.
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39-47

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)
0.49 0.69 0.85
0.57 0.73 0.89
0.61 0.77
0.65 0.81
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1) Using shim tolerances it is possible to find the
exact shim thickness required: insert two shims if
necessary.
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p://127.0.0.1:8080/audi/servlet/Dis
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yp
e=re
pair&id=AUDI.B5.TM01.39.5