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Home >> Audi >> 2006 >> A4 Cabriolet (8H7) L4-1.8L Turbo (AMB) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Differential >> Service and Repair >> Overhaul >> Final Drive, Differential (01X Transmission) >> Pinion Shaft Adjusting

Pinion Shaft Adjusting






Pinion Shaft Adjusting

Repairs after which the pinion shaft must be adjusted. Refer to => [ Adjustment Table ] Adjustment Table.

Special tools, testers and auxiliary items required

• Removal tool (VW 296)

• Holding plate (VW 309)

• Transmission support (VW 353)

• Universal measuring tool (VW 385)

• Dial gauge holder (VW 387)

• Thrust plate (VW 402)

• Press tool (VW 407)

• Thrust disc (VW 412)

• Assembly tool (VW 792)

• Thrust plate (2050)

• Thrust pad (3062)

• Press support-R&I wheel brg's. (3144)

• Press tool (3345)

• Torque wrench (VAG 1331)

• Dial gauge

• Dial gauge extension, 30 mm

Determining total shim thickness "Stotal " for shims "S3" plus "S 4"

(Setting preload of tapered roller bearings for pinion shaft)

• Differential removed.

- Press tapered roller bearing outer race for pinion shaft into transmission housing without shims.





- Press in tapered roller bearing outer race for pinion shaft with shim "S4*" (thickness 1.01 mm) into bearing housing.





• For measurement purposes a shim "S4" with a thickness of 1.01 mm is inserted provisionally. This is referred to in the following as "S4*". "S4*" is exchanged with the final shim "S4" after determining measured value "e".

- Secure transmission housing onto transmission support (VW 353) with bolts - arrows -.





- Press tapered roller bearing inner race - 1 - onto pinion shaft and secure, refer to => [ Pressing on tapered roller bearing inner race ] Pinion Shaft





- Install selector gears and locking collar for 1st and 2nd gears - 2 -. Refer to => [ Pinion Shaft ] Pinion Shaft.

- Press tapered roller bearing inner race - 3 - onto pinion shaft, refer to => [ Pressing on tapered roller bearing inner race ] Pinion Shaft

- Insert completely assembled pinion shaft in transmission housing.

- Install bearing housing and transmission cover with 4 dowel sleeves and tighten bolts to 35 Nm.

- Turn transmission so that the transmission cover points downward.

- Press down on face of pinion shaft with removal tool (VW 296) until tapered bearing outer race contacts bearing housing.





- Maintain pressure and rotate pinion shaft 5 turns in both directions to seat taper roller bearing.

- Attach dial gauge (3 mm measuring range) with dial gauge extension to transmission housing.





- Preload dial gauge to 1 mm and set to "0".

The dial gauge extension must contact machined surface on the face of pinion.

- Turn transmission so that the transmission cover points upward.





- Rotate pinion shaft 5 turns in each direction so that the tapered roller bearing seats properly. Otherwise the result of the measurement will be incorrect.

- Read off play on dial gauge and note reading.

• Measurement in example: 0.46 mm

• If the measuring procedure needs to be repeated, the pinion shaft must first be rotated 5 turns in each direction again so that the tapered roller bearing seats properly. Preload dial gauge to 1 mm and set to "0" again.

Formula: "Stotal" = "S4* " + measured value + bearing preload





Determining thickness of shim "S3* "

Formula: "S3*" = "Stotal" - " S4*"





- Pull tapered roller bearing outer race out of transmission housing, refer to => [ Pulling tapered roller bearing outer race out
of transmission housing ] Pinion Shaft

- Install shim "S3*" in transmission housing and install outer race again => [ (Item 3) Tapered roller bearing outer race ] Pinion Shaft Assembly Overview.

- Insert completely assembled pinion shaft into transmission housing again.

- Install bearing housing and transmission cover with the 4 dowel sleeves and tighten bolts to 35 Nm.

- Turn pinion shaft 5 turns in each direction so that taper roller bearings seat properly.

- Install assembly device (VW 792) on transmission housing; when doing so, insert a M12 nut - A - between assembly device (VW 792) and transmission housing.





- Install universal dial gauge bracket (VW 387) with dial gauge and 30 mm extension.

- Apply dial gauge extension exactly at center of intersection of ribs on transmission cover - arrow -.

- Set dial gauge (3 mm measuring range) to "0" with 1 mm preload.

- Loosen transmission cover bolts and turn pinion shaft several times.

- If correct shims have been selected the dial gauge will now indicate the following value:

• 0.06 to 0.12 mm

- Tighten transmission cover bolts again to 35 Nm.

- Take down measuring tools.

- Turn pinion shaft 5 turns in each direction so that taper roller bearings seat properly.

Determining dimension "e "

• Measurement "e" is required to determine the final shim thickness of "S3" and "S4".

- Set adjustment rings of universal measuring tool (VW 385/1) to the following values:





• Dimension - a - = 45 mm

• Dimension - b - = 75 mm

- Assemble universal measuring tool (VW 385/1 ) as illustrated:





• Dial gauge extension - VW 385/15 -, 6.5 mm long

• Master gauge (VW 385/30)

- Set master gauge (VW 385/30) to Ro = 59.65 mm and install onto measuring tool.

- Set dial gauge (3 mm measuring range) to "0" with 2 mm preload.

- Place end measuring plate on face of pinion shaft.





• Make sure plate contact surface fits exactly and is free of oil.

- Remove master gauge and insert measuring tool into housing.





• The dial gauge faces toward final drive cover

- Install cover for final drive and tighten 4 bolts to 20 Nm.

- Using adjustable ring, pull 2nd centering pad ( VW 385/36) out as far as possible so that the measuring tool can still just be turned by hand.

- Turn measuring tool until dial gauge point touches the end measuring plate on pinion shaft head, then measure maximum deflection (return point).





• Measurement in following example: "e" = 0.17 mm (in red scale)

• 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"

• The deviation (tolerance) "r" in relation to the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the crown wheel.

• Subtract value "e" if measurement is obtained on red scale.

• Add value "e" if measurement is obtained on black scale.

Formula:

"S3" = "S3*" + " r" + "e" ("e" on black scale)

"S3" = "S3*" + " r" - "e" ("e" on red scale)





- Determine shim(s) according to table. For part numbers

Available shims for "S3"





* The exact shim thickness required can be obtained by using the shim tolerance variations. Install two shims if necessary.

Determining thickness of shim "S4"

Formula: "S4" = "Stotal" - " S3"





- Determine shim(s) according to table. For part numbers

Shims available for "S 4"





* The exact shim thickness required can be obtained by using the shim tolerance variations. Install two shims if necessary.

Checking adjustment

Checking deviation (tolerance) "r "

- Install pinion shaft with appropriate measured shims "S 3" and "S4".

- Turn pinion shaft 5 turns in each direction so that taper roller bearings seat properly.

- Insert universal measuring tool and check adjustment.





- Read off dial gauge counterclockwise (red scale).

• If shims have been correctly selected, the deviation "r" (marked on outer circumference of crown wheel) should be indicated within a tolerance of ± 0.04 mm.
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