Determining total shim thickness "Stotal" for shims "S3" + "S4"

WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

(adjusting pre-load of tapered roller bearing for drive pinion)

Differential removed.

Fig 1: Pressing In Double Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Without shims press large tapered roller bearing outer race into transmission housing.
Insert rubber disc-item 40 and pressure plate-item 39 into transmission cover. Refer to Drive pinion, disassembling and assembling

Fig 2: Pressing In Outer Race For Small Tapered Roller Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press small tapered roller bearing outer race together with a 1.00 mm thick preliminary shim S4* into transmission cover.

NOTE: A shim "S4" with a thickness of 1.0 mm is installed for initial measurements. It is referred to as "S4*" in the following. After determining measurement "e", "S4*" will be replaced by the correct shim "S4".

Pressing on inner race for tapered roller bearing. Refer to Drive pinion, disassembling and assembling .

Fig 3: Identifying Lower Tapered Roller Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure lower tapered roller bearing (arrow). See Determining thickness of circlip

NOTE: Illustration shows drive pinion without gear wheels.

Insert assembled drive pinion in transmission housing.
Install transmission cover and tighten bolts to 22 Nm.
Turn transmission so that transmission cover is downward.

Fig 4: Pressing Down On Drive Pinion Head Using Removal Tool VW 296

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press down on face of drive pinion head with lever VW 296 until the tapered roller bearing outer race contacts the transmission cover.
Continue pressing on face of drive pinion head, at the same time turn drive pinion 8 turns by hand, so tapered roller bearing can settle.

Fig 5: Installing Dial Gauge (3 Mm Range) And Set To "0" With 2 Mm Pre-Load

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install dial gauge (3 mm measuring range) and set to "0" with 2 mm pre-load.

NOTE:

Use dial gauge extension 30 mm long.
The dial gauge extension must contact the machined surface on the face of pinion.

Turn transmission 180 ° so that the transmission cover is upward.
Rotate drive pinion 5 turns in both directions to settle the tapered roller bearing.

Fig 6: Turn Transmission 180 Degrees, Settle Tapered Roller Bearing And Read Play On Dial Gauge

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Read play on dial gauge and note reading.

Measurement in example: 0.45 mm

NOTE: If the measurement has to be repeated, drive pinion must first be rotated another5 turns in each direction to settle the tapered roller bearing. Reset dial gauge to "0" with 2 mm pre-load.

Formula:
"Stotal"

"S4*" + measurement + bearing pre-load

Example:
	Inserted shim "S4*"	1.00 mm
+	Measurement (example)	0.45 mm
+	Bearing pre-load (constant)	0.15 mm
=	Total shim thickness "Stotal" for "S3" + "S4"	1.60 mm