Redetermining "S4" After Replacing Transmission Cover

Special tools and equipment
- VW387 dial gauge holder
- VW792/1 assembly tool
- Dial indicator
- Dial indicator extension
- Depth gauge with minimum 5/100 mm precision

- Clean housing mating surfaces.





- Measure difference in depth "a" on old and new transmission cover.

Example:
Depth -a- (old transmission cover) 257.40 mm
Depth -a- (new transmission cover) 257.55 mm _____________

= Difference 0.15 mm

- Install thicker shim "S4" if new transmission cover is deeper.
- Install thinner shim "S4" when the old transmission cover is deeper.

Example:
Previous shim "S4" 0.95 mm
+ Difference 0.15 mm ____________

New shim "S4" 1.10 mm

Available shims, Pinion Shaft, Adjusting

- Install tapered roller bearing outer race with shim "S4" into transmission cover, Fig. 8 Pressing In Tapered Roller Bearing Outer Race
- Install fully assembled pinion shaft into transmission housing.
- Install transmission cover and tighten to 22 Nm (16 ft. lbs.).
- Preload for tapered roller bearing for pinion shaft, checking
- Turn pinion shaft 5 rotations in each direction to seat the tapered roller bearing.

Note: The pinion shaft can be fumed by simultaneously fuming both drive flanges.





- Install measuring tools and secure to transmission housing with bolt (arrow).
- Attach dial indicator (3 mm measuring range) to center of transmission cover and set to O with 2 mm preload.
- Loosen transmission cover bolts and turn pinion shaft.
- If correct shims have been selected, the dial indicator will now indicate the following value: 0.05 - 0.15 mm.
- Remove measuring tools.
- Coat sealing surfaces with thin layer of sealant AMV 188 001 02.
- Tighten transmission cover bolts to 22 Nm (16 ft. lbs.).