1999 AUDI A4 transmission

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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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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39-49

Re-determining "S4" after replacing
transmission cover


Special tools and equipment

VW387 dial gauge holder
VW792/1 assembly tool
Dial indicator
Dial indicator extension
Depth gauge with minimum 5/100 mm
precision

- Clean housing mating surfaces.

Example: - Measure difference in depth "a" on old and new transmission cover.
Depth -a- (old transmission cover) 257.40 mm
Depth -a- (new transmission cover) 257.55 mm
= Difference 0.15 mm
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39-50

- Install thicker shim "S4" if new transmission
cover is deeper.

- Install thinner shim "S4" when the old
transmission cover is deeper.

Example:

Previous shim "S4" 0.95 mm
+ Difference 0.15 mm
= New shim "S4" 1.10 mm
Available shims Page 39
-47
, table

- Install tapered roller bearing outer race with
shim "S4" into transmission cover Fig. 8
,
Page 35
-32
.

- Install fully assembled pinion shaft into
transmission housing.

- Install transmission cover and tighten to 22 Nm
(16 ft lb).
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39-51

Preload for tapered roller bearing for pinion
shaft, checking

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

Note:
The pinion shaft can be turned by simultaneously
turning both drive flanges.

- Install measuring tools and secure to transmission housing with bolt
(arrow).
- Attach dial indicator (3 mm 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, the dial indicator will now indicate
the following value: 0.05-0.15 mm.
- Remove measuring tools.
- Coat sealing surfaces with thin layer of sealant AMV 188 001 02.
- Tighten transmission cover bolts to 22 Nm (16 ft lb).
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39-53

Determining total shim thickness Stotal for
shims S1 + S2
(Adjust preload of tapered roller bearing for
differential)

Pinion shaft removed

Note:
If only the differential tapered roller bearings are
to be replaced, remove ring gear from differential
housing. The pinion shaft does not have to be
removed.

- Remove seals and outer races from both
tapered roller bearings for differential.

- Remove shims Page 39
-15
.

Note:
A shim S2 with a thickness of 1.20 mm is installed for initial measurement.
It is referred to in the following text as S2*. After determining backlash, S2*
is replaced with the appropriate shim S2. - Drive in tapered roller bearing outer race together with shim S2 into
transmission housing Fig. 3, Page 39
-23
. Use shim "S2*" with
1.20 mm thickness for measurement purposes (2 shims with 0.60 mm).
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39-54


- Press in tapered roller bearing outer race into differential cover without
shim S1 Fig. 9
, Page 39
-26
.
- Install differential into transmission housing without Vehicle Speed
Sensor (VSS) -G22- gear drive. Ring gear is located on left side in front
of final drive cover.
- Install cover for differential and tighten four bolts to 25 Nm (18 ft lb).
- Position transmission so that cover for differential faces upward.
- Turn differential 5 rotations in each direction to seat tapered roller
bearing.

Note:
Tip of dial indicator must be positioned on the center of the differential. - Assemble measuring equipment, use 30 mm dial indicator extension.
- Set dial indicator (3 mm measuring range) -A- to 0 with 2mm preload.
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g gear, ad
justin
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11/19/2002 htt
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yp
e=re
pair&id=AUDI.B5.TM01.39.5