Re-determining "S4" shim when installing new transmission cover
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.
Special tools, testers and auxiliary items required
- VW 387 Universal dial gauge holder
- VW 792 Assembly device
- Dial gauge
- Dial gauge extension
- Use depth gauge to within at least 5/100 mm.
- Clean housing flange.
- Measure difference in depth "a" on old and new transmission cover.
Example:
| Depth "a" on old transmission cover | 257.40 mm | |
| Depth "a" on new transmission cover | 257.55 mm | |
| = | Difference | 0.15 mm |
- Install thicker shim "S4" if new transmission cover is deeper.
- Install thinner shim "S4" if the old transmission cover is deeper.
Example:
| Previous shim "S4" | 0.95 mm | |
| + | Difference | 0.15 mm |
| = | New "S4" shim | 1.10 mm |
Available shims. Refer to table under The following shims are available for "S4" .
- Install outer race for tapered roller bearing with shim "S4" in transmission cover. See Pressing in outer race for small tapered roller bearing
- Insert completely assembled drive pinion in transmission housing again.
- Install transmission cover and tighten bolts to 22 Nm.
Checking pre-load of tapered roller bearing for drive pinion
- Rotate drive pinion 5 turns in both directions to settle the tapered roller bearing.
NOTE:
Drive pinion can be rotated by simultaneously turning both flange shafts.
- Install measuring tools and secure with bolt (arrow) to transmission housing.
- Position dial gauge (3 mm measuring range) center on transmission cover and set to "0" with 2 mm pre-load.
- Loosen transmission cover bolts and turn drive pinion several times.
If the correct shims have been selected the dial gauge will now indicate the following value:
- 0.05... 0.15 mm
- Remove measuring tools.
- Apply thin coat of sealant AMV 188 001 02 to sealing surfaces.
- Retighten transmission cover bolts to 22 Nm.