Defining total shim thickness "Stotal" of shims "S3" + "S4"

WARNING: This page is about a different car, the 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 pinion and hollow shaft)

Differential removed

Fig 1: Pinion Shaft Component, Overview

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Press inner race -1- of double tapered roller bearing onto pinion and secure. Refer to Pinion and hollow shaft, disassembling and assembling onward.

Install needle bearing -2-.
Position circlip -3- on hollow shaft and press on inner race of tapered roller bearing -4-. Refer to Pinion and hollow shaft, disassembling and assembling onward.
Insert pinion shaft in hollow shaft.

NOTE: In the illustration the hollow wheel is shown without gears. The pinion can be set either with or without gears.

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

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Insert outer race of double tapered roller bearing for pinion in transmission housing without shims.

Smaller diameter of pressure plate 3062 faces outer race.

Fig 3: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert outer race of pinion tapered roller bearing together with shim "S4*" (1.0 mm thick) in transmission cover.

NOTE:

A shim "S4" 1.0 mm thick is used provisionally as a reference value. It is referred to below as "S4*". Once measured value "e" has been determined, "S4*" will be replaced by actual shim "S4".
For measurement, always insert rubber washer together with ring for rubber washer. Refer to item 44 Pinion and hollow shaft, disassembling and assembling .

Insert fully assembled pinion and hollow shaft in transmission housing.
Install transmission cover and tighten bolts to 22 Nm.
Turn transmission so that transmission cover faces downward.

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

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Press head of pinion with lever VW 296 until outer race of tapered roller bearing makes contact with transmission housing.
Maintaining same pressure, rotate pinion in opposite direction to hollow shaft 5 turns in both directions, so that double tapered roller bearing slips into place.
Next, rotate pinion and hollow shaft together 5 turns in both directions, so that tapered roller bearing slips into place.

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

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Install dial indicator and set to "0" with 1 mm pre-load.

NOTE: Dial indicator extension must be situated on ground surface of pinion head.

Turn transmission 180 ° so that transmission cover faces upward.
Rotate pinion and hollow shaft together 5 turns in both directions, so that tapered roller bearing slips into place. Otherwise, measurement results will be incorrect.

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

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Read off and note down clearance indicated on dial indicator.

Example measured value: 0.45 mm

NOTE: If the measurement is repeated, first rotate the pinion and hollow shaft once more 5 turns in each direction. Set dial indicator to "0" with 1 mm pre-load once again.

Formula:
"Stotal"	=	"S4*" + measured value + bearing pre-load

Example:
	Inserted shim "S4*"	1.00 mm
+	measured value (example)	0.45 mm
+	bearing pre-load (constant value)	0.15 mm
=	Total shim thickness "Stotal" of "S3" + "S4"	1.60 mm