Determining dimension "e"

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.

NOTE: Measurement "e" is required to determine the final shim thickness of "S3" and "S4".

Fig 1: Setting Adjusting Rings Of Measuring Bar VW 385/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set adjustment rings of universal mandrel VW 385/1 to following measurements:

Dimension a = 35 mm
Dimension b = 75 mm

Fig 2: Assembling Measuring Bar VW 385/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assemble universal mandrel VW 385/1 according to illustration.

Dial gauge extension A	Ro	Ring gear diameter
6.5 mm	54.95	170 mm
9.3 mm	59.65	180 mm

Set master gauge VW 385/30 to Ro according to ring gear diameter and install onto mandrel.

Ring gear diameter 180 mm Ro = 59.65 mm

Ring gear diameter 170 mm Ro = 54.95 mm

Set dial gauge (3 mm measuring range) to zero with 2 mm pre-load.

Fig 3: Placing End Gauge On Drive Pinion Face

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place end measuring plate on face of drive pinion head.

NOTE: Make sure plate contact surface fits exactly and is free of oil.

Fig 4: Inserting Measuring Mandrel VW 385/1 Into Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove master gauge and insert measuring mandrel in housing.

With Ro = 54.95 mm, a dial gauge extension = 6.5 mm length must be screwed in instead of dial gauge extension VW 385/15.
The dial gauge faces cover for final drive

Install cover for final drive and tighten 4 bolts to 22 Nm.
Using sliding setting ring to pull 2nd centering disc outward until mandrel can still be turned by hand.

Fig 5: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion Shaft Head And Measure Maximum Runout

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn mandrel until the dial gauge point touches the end measuring plate on drive pinion head, then measure maximum deflection (return point).

Measurement in following example: "e" = 0.26 mm (in red scale on dial)

NOTE: After removing universal mandrel check again that the dial gauge, with master gauge VW 385/30 in place, indicates "0" with 2 mm pre-load.