Determining total shim thickness "Stotal" for shims "S1" + "S2"

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 differential)

Drive pinion removed

Pull out flange shaft oil seal with oil seal extractor VW 681.
Remove tapered roller bearing outer race for differential and remove shims. Refer to Differential, disassembling and assembling .

Fig 1: Pressing Outer Race/Tapered Roller Bearing Into Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive outer race for small tapered roller bearing with shim "S2" into transmission housing. For measurement purposes use a 1.20 mm thick "S2*" shim (2 shims of 0.60 mm).

NOTE: For measurement purposes a shim "S2" with a thickness of 1.20 mm is initially inserted. It is referred to as "S2*" in the following. After determining the backlash "S2*" will be replaced by the correct "S2".

Fig 2: Driving In Outer Race Of Tapered Roller Bearing Into Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press outer race for tapered roller bearing without shim "S1" into cover for differential.
Insert differential without drive wheel for speedometer sensor -G22- into transmission housing.
Install cover for differential with 4 bolts (25 Nm).
Position transmission so that cover for differential faces up.

Turn differential 5 turns in both directions to settle the tapered roller bearing.
Place measuring plate VW 385/17 onto differential.

Fig 3: Installing Magnetic Plate 50Mm Dia. VW 385/17 And Dial Gauge

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assemble measuring equipment, use a 30 mm dial gauge extension.
Set dial gauge (3 mm measuring range) to zero with 2 mm pre-load.

NOTE: The tip of the dial gauge must be positioned on center of differential.

Lift differential without turning; read play on dial gauge and note.

Measurement in following example: 0.62 mm

NOTE:

Fig 4: Securing Special Tools VW 521/4 And VW 521/12 At Right On Differential (Housing Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If measurement has to be repeated, differential must again be turned 5 turns in each direction to settle the tapered roller bearing.

Formula:
"Stotal"

"S2*" + measurement + bearing pre-load

Example:
	Inserted shim(s) "S2*"	1.20 mm
+	Measurement	0.62 mm
+	Bearing pre-load (constant)	0.30 mm
=	Total shim thickness "Stotal" for "S1" + "S2"	2.12 mm