Audi Workshop Service and Repair Manuals

Adjusting pinion shaft when deviation (tolerance) “e” is marked on outer circumference of crown wheel Special tools and workshop equipment required

t  Universal measuring tool -VW 385-

t  Torque wrench -V.A.G 1331- t  Depth gauge (e.g. digital depth gauge -VAS 6087-) t  Dial gauge Determining thickness of provisional shims “S3” and “S4.” l  Differential removed. l  Double angular contact ball bearing pressed onto the pinion shaft.   Note For measurement purposes a shim “S3” with a thickness of 1.00 mm is inserted provisionally. This is referred to in the following as “S3*”. “S3*” is exchanged with the final shim “S3” after setting dimension “e”. –  Secure gearbox housing onto gearbox support -VW 353- (gearbox housing must be in vertical position). –  Fit shim “S3*” in the gearbox housing.

–  Lubricate outer races -3- and -4- of double angular contact ball bearing with gear oil. –  Carefully push pinion shaft -1- with double angular contact ball bearing into gearbox housing -2- by hand (press down top outer race -3-).   Note Using hot air blower, heat area around seat of bearing in gearbox housing if necessary. Make sure that outer races -3- and -4- are kept straight when inserting and that they remain attached to each other. Otherwise the seal -6- can be damaged by the pinion gear -5-. The bearing must be renewed if the seal of the double angular contact ball bearing is damaged. Determine the provisional shim “S4” as follows:

–  Measure depth between double angular contact ball bearing outer race -1- and joint flange -2- for the retaining plate using digital depth gauge (e.g. digital depth gauge -VAS 6087-). In example: measurement -a- = 1.14 mm. Determine the provisional shim “S4” from table → Anchor.   Note For measurement purposes a shim “S4” with a thickness of 0.95 mm is inserted provisionally. This is referred to in the following as “S4*”. “S4*” is exchanged with the final shim “S4” after setting dimension “e”.

–  Position provisional shim “S4*” (0.95 mm in example) and the retaining plate -A- (only fits in one position) on joint flange in gearbox housing. –  Clean threads of old bolts -arrows- with a wire brush. Then tighten bolts in diagonal sequence to 30 Nm. Setting dimension “e”   Note Dimension “e” must be set to determine the final shim thickness of “S3” and “S4” for this particular final drive gear set.

–  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: t  Dial gauge extension -VW 385/16-, 12.3 mm long –  Set master gauge -VW 385/30- to dimension “Eo” = 62.17 mm and place onto universal measuring tool -VW 385/1-. –  Set dial gauge (3 mm measuring range) to “0” with 2 mm preload.

–  Place end measuring plate -VW 385/33- on face of pinion gear.   Note Ensure contact surface of end measuring plate -VW 385/33- fits exactly and is free of oil.

–  Detach master gauge -VW 385/30- and insert universal measuring tool in gearbox housing. t  Fit gauge extension -A- (length = 12.3 mm). t  The dial gauge faces towards the final drive cover l  The O-ring is fitted into cover for final drive. –  Fit cover for final drive and tighten 4 bolts to 24 Nm. –  Using the adjustable ring, pull 2nd centring disc -VW 385/36- out as far as possible so that the universal measuring tool can still just be turned by hand.

–  Turn universal measuring tool until the dial gauge pointer touches the end measuring plate on pinion gear, then measure maximum deflection (return point). t  Measurement in following example: = 0.43 mm (in red scale)   Note Then (after removing universal measuring tool), check once again that the dial gauge indicates “0” with 2 mm preload when master gauge -VW 385/30- is in place. Determining thickness of shim “S3” t  The dimension “e” in relation to the master gauge “Eo” is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the crown wheel → Chapter. t  Subtract value if measurement is obtained on red scale. t  Add value if measurement is obtained on black scale. Formula: “S3” = “S3*” + “e” + “measured value” (“measured value” on black scale) “S3” = “S3*” + “e” - “measured value” (“measured value” on red scale)

Example:
	Inserted shim “S3*”	1.00 mm
+	Dimension “e”	0.33 mm
-	Measured value (in red scale)	0.43 mm
=	Thickness of shim “S3”	0.90 mm

–  Determine shim(s) according to table. Part numbers → Electronic parts catalogue “ETKA”. Available shims for “S3”

Shim thickness (mm) → Note
0.55	0.75	0.95
0.60	0.80	1.00
0.65	0.85	1.05
0.70	0.90

1)  The exact shim thickness required can be obtained by using the shim tolerance variations. Install two shims if necessary. –  Remove provisional shims “S3*” and “S4*”. –  Fit determined shim “S3” (0.90 mm in example) in gearbox housing. Determining thickness of shim “S4” l  Determined shim “S3” is fitted in gearbox housing.

–  Lubricate outer races -3- and -4- of double angular contact ball bearing with gear oil. –  Carefully push pinion shaft -1- with double angular contact ball bearing into gearbox housing -2- by hand (press down top outer race -3-).   Note Using hot air blower, heat area around seat of bearing in gearbox housing if necessary. Make sure that outer races -3- and -4- are kept straight when inserting and that they remain attached to each other. Otherwise the seal -6- can be damaged by the pinion gear -5-. The bearing must be renewed if the seal of the double angular contact ball bearing is damaged. Determine the shim “S4” as follows:

–  Measure depth between double angular contact ball bearing outer race -1- and joint flange -2- for the retaining plate using digital depth gauge (e.g. digital depth gauge -VAS 6087-). In example: measurement -a- = 1.04 mm. Determine the shim “S4” from table → Anchor. Shims available for “S4”

Gap -a-	Shim “S4” → Note
Measured value (mm)	Thickness (mm)
0.67 … 0.71 0.72 … 0.76 0.77 … 0.81	0.50 0.55 0.60
0.82 … 0.86 0.87 … 0.91 0.92 … 0.96	0.65 0.70 0.75
0.97 … 1.01 1.02 … 1.06 1.07 … 1.11	0.80 0.85 0.90
1.12 … 1.16 1.17 …1.21 1.22 … 1.26	0.95 1.00 1.05
1.27 … 1.31 1.32 … 1.36 1.37 … 1.41	1.10 1.15 1.20
1.42 … 1.46 1.47 … 1.51 1.52 … 1.56	1.25 1.30 1.35
1.57 … 1.61	1.40

2)  The exact shim thickness required can be obtained by using the shim tolerance variations. Install two shims if necessary.   Note Select correct shims from → Electronic parts catalogue “ETKA”.

–  Position determined shim “S4” (0.85 mm in example) and the retaining plate -A- (only fits in one position) on joint flange in gearbox housing. –  Then tighten bolts -arrows- in diagonal sequence to 30 Nm. Checking dimension “E” –  Install pinion shaft with appropriate measured shims “S3” and “S4”.

–  Insert universal measuring tool and check adjustment. –  Read off dial gauge anti-clockwise (red scale). t  If the shims have been correctly selected, the dimension “e” (marked on outer circumference of crown wheel) should be indicated within a tolerance of ± 0.04 mm.   Note Then (after removing universal measuring tool), check once again that the dial gauge indicates “0” with 2 mm preload when master gauge -VW 385/30- is in place.