Re-determining shim "S4" when replacing bearing housing

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Dial Gauge Holder VW 387

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Universal dial gauge bracket VW387

Fig 2: Installation Arbor VW 792

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assembly tool VW792
Digital depth gauge (e.g. VAS 6087)
Dial gauge
Dial gauge extension, 30 mm

Straightedge

Clean housing flange.

Fig 3: Measuring Difference Between Depth On Old And New Bearing Housing With A Digital Depth Gauge

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place straightedge (e.g. 19.50 mm wide - 1 - onto housing flange.
Measure difference between depth - a - on old and new bearing housing with a digital depth gauge (e.g. VAS 6087).

Example:

	Depth - a - of previous bearing housing (with straightedge width)	26.30 mm
	Depth - a - of new bearing housing (with straightedge width)	26.45 mm
=	Difference	0.15 mm

If new bearing housing is deeper, install a thicker "S₄ " shim.
If previous bearing housing is deeper, install a thinner "S₄ " shim.

Example:

	Previous shim "S₄ "	0.95 mm
+	Difference	0.15 mm
=	New shim "S₄ "	1.10 mm

Shims available.

Press tapered roller bearing outer race with shim "S₄ " into bearing housing Pressing tapered roller bearing outer race into bearing housing
Insert completely assembled pinion shaft into transmission housing again.
Install bearing housing and transmission cover and tighten bolts to 35Nm.
Turn pinion shaft 5 turns in each direction so that taper roller bearings seat properly.

Fig 4: Identifying Assembly Device VW 792, M12 Nut, VW 387 And Transmission Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install assembly device VW 792 on transmission housing; when doing so, insert an M12 nut - A - between assembly device VW 792 and transmission housing.
Attach universal dial gauge bracket VW 387 with dial gauge and 30 mm extension.

NOTE:

Attach dial gauge extension exactly at the center of the webbing intersection on the transmission cover - arrow -.

Set dial gauge (3 mm measuring range) to "0" with 1 mm preload.
Loosen transmission cover bolts and turn pinion shaft several times.
If correct shims have been selected the dial gauge will now indicate the following value:

0.06 to 0.12 mm

If this reading is not obtained, the adjustment must be corrected.