Defining dimension "e"

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.

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

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adjust set rings of multi-purpose measuring mandrel VW 385/1 to following values:

Dimension a = 35 mm
Dimension b = 75 mm

Fig 2: Assembling Measuring Bar VW 385/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assemble multi-purpose measuring mandrel VW 385/1 as shown in illustration:

Dial indicator extension -A-, 6.5 mm long

Adjust controller VW 385/30 to Ro in line with ring gear diameter and place on measuring mandrel.

Ring gear diameter 170 mm = 54.95 mm

Set dial indicator (3 mm measuring range) to "0" with 2 mm pre-load.

Fig 3: Placing End Gauge On Drive Pinion Face

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place gauge block plate on pinion head.

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

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove controller and insert measuring mandrel in housing.

Dial indicator extension -A- = 6.5 mm long must be screwed in
Dial indicator faces cover of final drive

Position cover of final drive and tighten 4 bolts to 22 Nm.
Pull 2nd centering disc outward using moveable set ring until measuring mandrel can only just 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 measuring mandrel until tip of dial indicator runs into gauge block plate on pinion head and gauge displays maximum deflection (point of return).

Measured value in following example: "e" = 0.26 mm (red zone)

NOTE: After removing multi-purpose measuring mandrel, check again whether dial indicator with controller VW 385/30 in position is still set to "0" with 2 mm pre-load.