Audi Workshop Service and Repair Manuals

Re-determining shim “S6” for positioning 2nd speed selector gear Shim -A- is responsible for the correct positioning of 2nd speed selector gear and thus the positioning of the gear assembly in the gearbox. This adjustment is necessary when the following components are renewed: t  Gearbox housing t  Final drive gear set t  Hollow shaft or the t  Gear wheels on hollow shaft Special tools and workshop equipment required

t  Universal measuring tool -VW 385-

t  Straightedge -T 40100- t  Digital depth gauge (e.g. -VAS 6087-)

–  Set adjustment rings of universal measuring tool -VW 385/1- to the following values: t  Dimension -a- = 45 mm t  Dimension -b- = 60 mm

–  Assemble universal measuring tool -VW 385/1- as illustrated: Determining dimension -A- l  Tapered roller bearing outer races for differential bearings are installed in gearbox housing and cover for final drive. –  Insert universal measuring tool -VW 385/1- with centring disc -VW 385/4- facing towards gearbox housing. –  Fit cover for final drive with O-ring installed and and tighten four bolts to 24 Nm. –  Using the adjustable ring, move the centring disc outwards until it is no longer possible to turn the universal measuring tool by hand. l  The round side of universal measuring tool must point up towards depth gauge during this procedure.

–  Position straightedge -T 40100- onto cleaned joint surface of gearbox housing. –  Measure depth between straightedge and highest point on universal measuring tool -VW 385/1- using depth gauge -1- (e.g. digital depth gauge -VAS 6087-). In example: measurement -a- = 143.80 mm. –  Subtract height of straightedge -T 40100- from this measurement and add half the Ø of universal measuring tool -VW 385/1- to this calculation. This value is 16 mm.

Example:
	Depth as measured with digital depth gauge	143.80 mm
-	Height of straightedge -T 40100-	40.00 mm
+	half the Ø of universal measuring tool -VW 385/1-	16.00 mm
=	Dimension -A-	119.80 mm

Determining dimension -B- l  Pinion shaft is fitted with shims “S3” and “S4”.

l  The securing bolts -arrows- for the retaining plate are tightened to 30 Nm. –  Install input shaft, hollow shaft with pressed-on roller bearings and bearing mounting -1-. –  Position straightedge -T 40100- onto cleaned joint surface of gearbox housing. –  Measure depth between roller bearing inner race and straightedge using digital depth gauge -2- (e.g. digital depth gauge -VAS 6087-). In example: measurement -b- = 172.00 mm. –  Add the height of straightedge -T 40100- to this measurement.

Example:
	Depth as measured with digital depth gauge	172.00 mm
+	Height of straightedge -T 40100-	40.00 mm
=	Dimension -B-	212.00 mm

Determining thickness of shim “S6” Formula: measuring range (overall dimension) = dimension -A- + dimension -B-

Example:
	Dimension -A-	119.80 mm
+	Dimension -B-	212.00 mm
=	Measuring range (overall dimension)	331.80 mm

Select required shim from table → Anchor.

Measuring range (overall dimension)	Shim “S6”
Measured value (mm)	Thickness (mm)
331.38 … 331.43	4.70
331.44 … 331.53	4.60
331.54 … 331.63	4.50
331.64 … 331.73	4.40
331.74 … 331.83	4.30
331.84 … 331.93	4.20
331.94 … 332.03	4.10
332.04 … 332.08	4.00

Note Select correct shims from → Electronic parts catalogue “ETKA”. –  The shim thickness “S6” in this example is 4.30 mm.