Determining thickness of shim when replacing hollow shaft

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.

Use a caliper gauge accurate to within at least 5/100 mm.

Fig 1: Locating Clamping Sleeve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten spring pin to exactly 10 Nm.

A - Vice clamps

Fig 2: Setting End Gauge VW 385/32 Onto Pinion Face

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Place end measuring plate VW 385/32 onto drive pinion head and measure dimension "d".

Top measuring point is shoulder for inner race of small taper roller bearing.
Example: 248.50 mm

Install new hollow shaft and once again measure dimension "d".

Example: 248.70 mm

Fig 3: Setting End Gauge VW 385/32 Onto Pinion Face

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Determine the difference:

Dimension "d" of old hollow shaft	248.50 mm
Dimension "d" of new hollow shaft	248.70 mm
Difference	= 0.20 mm

Install appropriately thinner shim S4 if dimension "d" of new hollow shaft is larger.
Install appropriately thicker shim S4 if dimension "d" of new hollow shaft is smaller.