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

39-158

Note:
Before performing following measurements turn
drive pinion at least five turns in both directions,
so that the tapered roller bearings settle.
Otherwise a false reading will be obtained.

- Place end measuring plate VW 385/33 onto drive pinion head.

- Remove master gauge and insert measuring mandrel in the housing.
The centering disc VW 385/3 faces toward cover for final drive
- Fit cover for final drive and tighten 4 bolts.
- Using adjustable ring, move 2nd centering disc out as far as possible
so that mandrel can still just be turned by hand.
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39-159

Determining measurement "e"

Note:
Dimension "e" is required to determine thickness of shim "S3."
Determining shim thickness "S3" - Turn mandrel until dial gauge point touches end measuring plate on
drive pinion head, then measure maximum deflection (return point).
Measured value is dimension "e" (in red scale).

Measurement in following example: "e" = 1.60 mm
- After removing universal mandrel, check once again whether dial
gauge reads "0" with 2 mm preload when master gauge VW 385/30 is
in place, otherwise repeat measurement.
Formula:
"S3"
=
"e" - "r"
e
=
Measured value
r
=
Deviation (tolerance): marked on ring gear in 1/100 mm
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39-160

Example:

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

- Determine shim(s) as accurately as possible
from table.

Parts catalog
The following shims are available for "S3"

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

- Remove universal mandrel.
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39-161

- Remove drive pinion and outer race of large
tapered roller bearing and install together with
measured shims "S3" and spacer sleeve from
Page 39
-139
.
Install inner race of small tapered roller bearing
and tighten nut for drive pinion until specified
friction torque is obtained
Fig. 11 , Page 39
-144
.

Note:

Do not additionally oil new tapered roller
bearings for friction torque measurement. The
bearings have already been treated with a
special oil by the manufacturer.
Increase tightening torque slowly and check
friction torque at regular intervals, if the
specified friction torque is exceeded, the spacer
sleeve must be replaced and the adjustment
repeated. A spacer sleeve which has been
compressed too much cannot be reused.

- Set to following friction torques:

New bearings
Used bearings
1)
200-250 Ncm 30-60 Ncm
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1) run at least 50 km (30 miles)
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39-162

Performing check measurement

Checking dimension "r"

- Turn drive pinion at least 5 turns in both
directions.

- Insert universal mandrel and perform check measurement.
If the shims have been correctly selected, the dial gauge should now
show the value of "r" as marked on the ring gear, reading anti-
clockwise in the red scale, within a tolerance of 0.04 mm.

- Peen drive pinion nut with a punch.
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39-163

Ring gear, adjusting

(Adjusting differential)
Repairs after which the ring gear has to be
adjusted Page 39
-150
, Adjustment overview

Note:

Differential tapered roller bearings are low
friction bearings. Therefore the friction torque
only has 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
bearings for friction torque measurement. The
bearings have already been treated with a
special oil by the manufacturer.

Determining total shim thickness "S
total
" for
shims "S1" + "S2"
(Setting preload of tapered roller bearing for
differential)

Drive pinion removed or ring gear dismantled
from differential housing

- Pull out drive flange oil seal with lever.
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- Remove differential tapered roller bearing outer
races and take out shims Page 39
-120
.
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