2000 AUDI A6 01E Transmission Final Drive Pinion Adjustment Workshop Manual

39-45

Determining measurement "e"

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

- Set adjustment rings of universal mandrel VW 385/1 to the following
measurements:

Dimension a = 65 mm
Dimension b = 55 mm

- Assemble universal mandrel VW 385/1 as illustrated:

Dial gauge extension VW 385/15, 9.3 mm long
Master gauge VW 385/30
- Set master gauge VW 385/30 to Ro = 59.65 mm and fit onto mandrel.
- Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.
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39-46

Note:
The gauge VW 385/27 can also be used in place
of the master gauge VW 385/30 (Ro = 59.65
mm).

Arrangement of measuring equipment when determining dimension "e"
Note:
Ensure plate contact surface fits exactly and is free of oil. - Place end measuring plate VW 385/17 onto drive pinion head.
- Take master gauge off mandrel.
- Insert mandrel into transmission housing.

The centering disc 385/3 faces toward cover for final drive
- Fit cover for final drive and tighten 4 bolts to 25 Nm.
- Using adjustable ring, pull 2nd centering disc VW 385/2 out as far as
possible so that mandrel can still just be turned by hand.
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39-47


Determining thickness of shim "S3"
Note: - Turn mandrel until dial gauge plunger tip touches end measuring plate
on drive pinion head, then measure maximum deflection (return point).

Measurement in following example: "e" = 0.16 mm (in red scale)
Formula:
"S3"
=
"S3*" + "r" + "e"
("e" in black scale)
or
"S3"
=
"S3*" + "r" - "e"
("e" in red scale)
The deviation "r" related to the master gauge "Ro" is measured for the
final drive sets supplied as replacement parts and inscribed on outer
circumference of ring gear. If measurements are obtained on red scale then subtract value "e."If measurements are obtained on black scale then add value "e."
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39-48

Example:

Inserted shim "S3*" 1.05 mm
+ Deviation "r" 0.38 mm
- Determined "e" (in red scale)
0.16 mm
=
Thickness of shim "S3" 1.27 mm

- Determine shim(s) from table.

Parts catalog
The following shims are available for "S3"

Shim thickness (mm)
1)
0.45 0.60 0.75
0.50 0.65
0.55 0.70

1) Using the shim tolerance variations it is
possible to find the exact shim thickness
required, insert two shims if necessary.
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39-49

Determining thickness of shim "S4"

Formula:
"S4"
=
"S
total
" - "S3"

Example:


Total shim thickness "S
total
"
for "S3" + "S4"
2.05 mm
- Thickness of shim "S3" 1.27 mm
= Thickness of shim "S4" 0.78 mm

- Determine shim(s) from table.

Parts catalog

The following shims are available 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
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1) Using the shim tolerance variations it is
possible to find the exact shim thickness
required, insert two shims if necessary.
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39-50

Performing check measurement

Checking dimension "r"

- Install drive pinion with determined shims "S3"
and "S4" and turn 5 turns in both directions.

Note:
Then, (after removing universal mandrel) check again that the dial gauge,
with master gauge VW 385/30 in place, indicates "0" with 2 mm preload,
otherwise correct adjustments. - Insert universal mandrel, Page 39
-45
, "determining measurement
'e'" and perform check measurement.
- Read off dial gauge anti-clockwise (red scale).

If the shims have been correctly selected, the deviation "r" (marked
on outer circumference of ring gear) must be shown - within a
tolerance of 0.04 mm
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39-51

Measuring friction torque (check)

Note:

Drive pinion/hollow shaft tapered roller bearings
are low friction bearings. Therefore the frictional
torque has only a limited use as a check.
Correct adjustment is only possible by
determining the total shim thickness "S
total
."

Do not additionally oil new tapered roller
bearing to perform the frictional torque
measurement. These bearings have already
been treated with a special oil by the
manufacturer.

Frictional torque specification: - Fit torque gauge 0-600 Ncm -A- onto drive pinion.
B - Socket
- Insert tensioning sleeve 3116.New bearings
Used bearings
80-150 Ncm 30-60 Ncm
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