Audi Workshop Service and Repair Manuals

Re-determining shim “S4” when renewing gearbox cover Special tools and workshop equipment required

t  2 x centring disc -VW 385/3-

t  End measuring plate -VW 385/17-

t  Universal dial gauge bracket -VW 387-

t  Assembly device -VW 792- t  Dial gauge t  Dial gauge extension t  Depth gauge (accurate to within 5/100 mm or less) –  Clean housing flanges.

–  Measure difference in depth “a” on old and new gearbox cover. Example:

	Depth “a” (old gearbox cover)	257.40 mm
	Depth “a” (new gearbox cover)	257.55 mm
=	Difference	0.15 mm

–  If new gearbox cover is deeper, install a thicker “S4” shim. –  If previous gearbox cover is deeper, install a thinner “S4” shim. Example:

	Previous shim “S4”	0.95 mm
+	Difference	0.15 mm
=	New shim “S4”	1.10 mm

Shims available → . –  Fit tapered roller bearing outer race with shim “S4” in gearbox cover → Fig.. –  Insert completely assembled pinion shaft into gearbox housing again. –  Fit gearbox cover and tighten bolts to 22 Nm. –  To settle the tapered roller bearings: rotate pinion shaft together with hollow shaft 5 turns in each direction, then rotate pinion shaft separately in relation to hollow shaft 5 turns in each direction.

–  Set up measuring tools and secure with bolt -arrow- to gearbox housing. –  Set dial gauge (3 mm measuring range) 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: t  0.05 ... 0.15 mm If this reading is not obtained, the adjustment must be corrected.