Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary equipment required

• ◆ Universal dial gauge bracket VW 387
• ◆ Fitting tool VW 792/1
• ◆ Dial gauge
• ◆ Dial gauge extension
• ◆ Depth gauge (accurate to within at least 5/100 mm)

• ‒ Clean housing flange.
• ‒ → Measure difference in depth "a" on old and new gearbox cover.

Example:

• ‒ Install thicker shim "S4" if the new gearbox cover is deeper.
• ‒ Install thinner shim "S4" if the old gearbox cover is deeper.

Example:

Available shims => table on Page 39-53.

• ‒ Install taper roller bearing outer race with shim "S4" in gearbox cover => Fig.35-38.
• ‒ Insert completely assembled pinion shaft in gearbox housing again.
• ‒ Fit gearbox cover and tighten bolts to 22 Nm.

Checking preload of taper roller bearing for drive pinion

• ‒ Rotate pinion shaft 5 turns in both directions to settle the taper roller bearing.

Note:

The pinion shaft can be rotated by turning both flange shafts together.

• ‒ → Fit measuring tools and secure with bolt (arrow) to gearbox housing.
• ‒ Fit dial gauge (3 mm measuring range) onto centre of gearbox cover and set to "0" with 2 mm preload.
• ‒ Loosen gearbox cover bolts and turn pinion shaft several times.
• ‒ If the correct shims have been selected the dial gauge will now indicate the following value:
• ‒ 0.05 ... 0.15 mm
• ‒ Remove measuring tools.
• ‒ Apply thin coat of sealant AMV 188 001 02 to sealing surfaces.
• ‒ Retighten gearbox cover bolts to 22 Nm.