FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Audi >> 2007 >> A4 Quattro Wagon (8ED) L4-2.0L Turbo (BWT) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Differential >> Service and Repair >> Overhaul >> Final Drive, Differential (02XA Transmission) >> Pinion, Adjusting

Pinion, Adjusting






Pinion, Adjusting

Special tools, testers and auxiliary items required

• Removal Tool (VW 296)

• Holding Plate (VW 309)

• Transmission Support (VW 353)

• Universal Measuring Device (VW 385)

• Dial Gauge Holder (VW 387)

• Pressure Plate (VW 402)

• Punch (VW 407)

• Punch (VW 412)

• Alignment Fixture (VW 792)

• Thrust Piece (2050)

• Thrust Pad (3062)

• Sleeve (3144)

• Tube for Wheel Bearing (3345)

• Torque Wrench (V.A.G 1331)

• Dial gauge

• Dial gauge extension 30 mm

• Hose clamp

Determine total shim thickness "Stotal" for adjustment shims "S3" + "S4"

(adjust preload of tapered roller bearing for drive pinion with hollow shaft)

• Differential removed

- Press inner race - 1 - for double tapered roller bearing onto drive pinion and secure. Refer to => [ Installing the Inner Race/Double Tapered Roller Bearing ] Pinion and Hollow Shaft.





- Install the large needle bearing - 2 -.

- Insert pinion shaft into hollow shaft - 3 -.

• The hollow shaft is assembled with the gear wheels and inner race/raper roller bearing.

- Install the small needle bearing - 4 -.

- Install the pinion outer race/double tapered roller bearing into the transmission without the shims.





- Install the outer race/tapered roller bearing for the pinion/hollow shaft with shim "S4*" (1.01 mm thick) into the bearing housing.





• For the initial measurement, an adjustment shim "S4" of 1.01 mm is inserted. It is designated as "S4*" in the following. After determining the measured value "e", " S4*" is replaced by the final adjustment shim " S4".

- Secure the transmission housing to the Transmission Support (VW 353) with the bolts - arrows -.





- Install fully assembled drive pinion with hollow shaft into transmission housing.

- Mount the bearing housing and the transmission cover and tighten the bolts to 35 Nm.

- Turn transmission so that the transmission cover points downward.

- Press onto drive pinion face using Removal Tool ( VW 296) until outer race of tapered roller bearing makes contact in the bearing housing.





- While maintaining pressure, rotate drive pinion 5 rotations each in both directions in opposite direction of hollow shaft so that double tapered roller bearing settles.

- Then, turn drive pinion with hollow shaft 5 rotations in both directions to settle the hollow shaft tapered roller bearing.

- Turn transmission so that the transmission cover points upward.

- Then, turn drive pinion with hollow shaft 5 rotations in both directions to settle the double tapered roller bearing. Otherwise, measurement will result in false readings.

- Install the measuring tool.





- Secure the pinion to the hollow shaft with a hose clamp - arrow -.

- Set gauge (3 mm measuring range) to "0" with 1 mm pre-load.

- Move the pinion - A - and hollow shaft up and down in direction of - arrow -.





- Read play on dial indicator and note.

• Measured value in the example: 0.46 mm

• If measurement is repeated, drive pinion with hollow shaft must first be rotated 5 complete rotations in both directions again to settle double tapered roller bearing. Set dial gauge again to "0" with 1 mm pre-load.

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





Determining thickness of adjustment shim "S 3*"

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





- Remove outer race/double tapered roller bearing, insert adjustment shim "S3*" into transmission housing and reinstall outer race => [ (Item 3) Outer race/double tapered roller bearing ] Pinion Shaft and Hollow Shaft Assembly Overview.

- Install fully assembled drive pinion with hollow shaft into transmission housing.

- Mount the bearing housing and the transmission cover and tighten the bolts to 35 Nm.

- Turn drive pinion with hollow shaft against hollow shaft 5 rotations in both directions to settle the tapered roller bearings.

- Install the measuring tools, use the 30 mm dial gauge extension - A -, secure the bolt - arrow - to the transmission housing and place an M12 nut between the (VW 792) and the transmission housing.





• Mount the dial gauge extension - A - on the ridge in the transmission cover.

- Set gauge (3 mm measuring range) to "0" with 1 mm pre-load.

- Loosen the bolts on the transmission cover and turn the pinion.

- Dial gauge must now display the following value for correctly selected adjustment shims:

• 0.09 to 0.18 mm

- Tighten the transmission cover bolts to 35 Nm.

- Remove the measuring tools.

- Turn drive pinion with hollow shaft against hollow shaft 5 rotations in both directions to settle the tapered roller bearings.

Determining dimension "e "

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

- Set adjustment rings of Universal Mandrel (VW 385/1 ) to the following values:





• Dimension - a - = 45 mm

• Dimension - b - = 75 mm

- Assemble Universal Mandrel (VW 385/1) as shown in the illustration:





• Dial gauge extension (VW 385/15), 9.3 mm long

• Adjustable Master Gauge (VW 385/30)

- Set Adjustable Master Gauge (VW 385/30) to Ro = 59.65 mm and set it onto the measuring bar.

- Set gauge (3 mm measuring range) to "0" with 2 mm pre-load.

- Place magnetic plate onto drive pinion face.





• Make sure gauge contact surface is precisely installed and free of oil.

- Remove master gauge and insert measuring mandrel into housing.





• A dial gauge extension - A - = 9.3 mm long must be screwed in.

• Dial gauge faces final drive cover.

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

- Using adjustable ring, pull 2nd Centering Disc ( VW 385/36) out far enough, so that the mandrel can only just be turned by hand.

- Turn measuring mandrel until dial indicator plunger tip touches end gauge on pinion shaft head and measure the maximum runout (return point).





• Measured value in following example: "e" = 0.26 mm (red numbered area)

• After removing universal measuring bar - check again whether dial gauge stands at "0" with 2 mm pre-load when adjustable master gauge (VW 385/30) is attached.

Determining thickness of adjustment shim "S 3"

• The deviation, or tolerance "r" which is based on the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear.

• If measured in red numbered area, measured value "e" must be subtracted.

• If measured in black numbered area, measured value "e" must be added.

Formula:

"S3" = "S3*" + " r" + "e" ("e" in black numbered area)

"S3" = "S3*" + " r" - "e" ("e" in red numbered area)





- Determine shim(s) according to table.

Available adjustment shims for "S3"





Determining thickness of adjustment shim "S 4"

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





- Determine shim(s) according to table.

Available adjustment shims for " S4"





Checking Measurement

Check dimension "r"

- Install drive pinion with hollow shaft with measured out adjustment shims "S3" and "S4".

- Turn hollow shaft against pinion 5 revolutions in both directions so that double tapered roller bearing settles.

- Then, turn drive pinion with hollow shaft 5 rotations in both directions to settle the tapered roller bearing.

- Install Universal Mandrel and perform measurement check.





- Read dial indicator counterclockwise (red numbered area).

• If shims have been determined correctly, deviation "r" (as marked on outer circumference of ring gear) should be indicated on dial within a tolerance of ± 0.04 mm.
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