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.

Dial gauge holder VW387

Fig 2: Installation Arbor VW 792

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installation arbor 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 .
Re-install fully assembled pinion shaft with hollow shaft into transmission housing.
Install bearing housing and transmission cover and tighten bolts to 35Nm.
To settle tapered roller bearings: rotate pinion shaft together with hollow shaft 5turns in each direction, then rotate pinion shaft separately in relation to hollow shaft 5 turns in each direction.

Fig 4: Determining Thickness Of Shim S3

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set up measuring tools using dial gauge extension 30 mm - A - ; place nut M12 between VW 792 and transmission housing when securing bolt - arrow - to transmission housing.

NOTE:

Place dial gauge extension - A - onto web in transmission cover.

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:

0.09 to 0.18 mm

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