Adjusting pinion shaft (output shaft): Audi A6 C6

🧭 Before you start

Fits: Audi A6 C6 (4F, 2004–2011)

• Special tools named: dial gauge
• Also covered elsewhere: Electronic parts catalogue

Don't miss

• For measurement purposes a shim "“S"4” with a thickness of 1.01 mm is inserted provisionally. This is referred to in the following as "“S"4*”. "“S"4*” is exchanged with the final shim "“S"4” after determining measured value "“e”".
• If the measuring procedure needs to be repeated, the pinion shaft must first be rotated 5 turns in each direction again so that the tapered roller bearing seats properly. Preload dial gauge to 1 mm and set to "“0”" again.
• Apply dial gauge extension exactly at centre of intersection of ribs on gearbox cover (arrow).
• Measurement "“e”" is required to determine the final shim thickness of "“S"3” and "“S"4”.
• Ensure contact surface of end measuring plate fits exactly and is free of oil.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Press tapered roller bearing outer race for pinion shaft into gearbox housing without shims.
2. Press in tapered roller bearing outer race for pinion shaft with shim "“S"4*” (thickness 1.01 mm) into bearing housing. [Note: For measurement purposes a shim "“S"4” with a thickness of 1.01 mm is inserted provisionally. This is referred to in the following as "“S"4*”. "“S"4*” is exchanged with the final shim "“S"4” after determining measured value "“e”".]
3. Secure gearbox housing onto gearbox supportVW 353 with bolts (arrows).
4. Press tapered roller bearing inner race (1) onto pinion shaft and secure .
5. Fit selector gears and locking collar for 1st and 2nd gears (2).

6. Press tapered roller bearing inner race (3) onto pinion shaft .
7. Insert completely assembled pinion shaft in gearbox housing.
8. Fit bearing housing and gearbox cover with the 4 dowel sleeves and tighten bolts to 35 Nm. — 35 Nm (26 lb-ft)
9. Turn gearbox so that the gearbox cover points downwards.
10. Press down on face of pinion shaft with transmission removal leverVW 296 until the tapered bearing outer race contacts the bearing housing.
11. Maintain pressure and rotate pinion shaft 5 turns in both directions to seat tapered roller bearing.
12. Fit dial gauge (3 mm measuring range) with 30 mm dial gauge extension to gearbox housing.
13. Preload dial gauge to 1 mm and set to "“0”".
14. Turn gearbox so that the gearbox cover points upwards.
15. Rotate pinion shaft 5 turns in each direction so that the tapered roller bearing seats properly. Otherwise the result of the measurement will be incorrect.
16. Read off play on dial gauge and note reading. [Note: If the measuring procedure needs to be repeated, the pinion shaft must first be rotated 5 turns in each direction again so that the tapered roller bearing seats properly. Preload dial gauge to 1 mm and set to "“0”" again.]
17. Remove tapered roller bearing outer race from gearbox housing .
18. Fit shim "“S"3*” in gearbox housing and install outer race again .
19. Insert completely assembled pinion shaft into gearbox housing again.
20. Fit bearing housing and gearbox cover with the 4 dowel sleeves and tighten bolts to 35 Nm. — 35 Nm (26 lb-ft)
21. Turn pinion shaft 5 turns in each direction so that tapered roller bearings seat properly.
22. Attach assembly deviceVW 792 to gearbox housing; when doing so, insert an M12 nut (A) between assembly device VW 792 and gearbox housing.
23. Fit universal dial gauge bracketVW 387 with dial gauge and 30 mm extension. [Note: Apply dial gauge extension exactly at centre of intersection of ribs on gearbox cover (arrow).]
24. Set dial gauge (3 mm measuring range) to "“0”" with 1 mm preload.
25. Loosen gearbox cover bolts and turn pinion shaft several times.
26. If the correct shims have been selected the dial gauge will now indicate the following value:
27. Tighten gearbox cover bolts again to 35 Nm. — 35 Nm (26 lb-ft)
28. Take down measuring tools.
29. Turn pinion shaft 5 turns in each direction so that tapered roller bearings seat properly. [Note: Measurement "“e”" is required to determine the final shim thickness of "“S"3” and "“S"4”.]
30. Set adjustment rings of universal measuring toolVW 385/1 to the following values:
31. Assemble universal measuring toolVW 385/1 as illustrated:
32. Set master gaugeVW 385/30 to Ro = 59.65 mm and fit onto universal measuring tool.
33. Set dial gauge (3 mm measuring range) to "“0”" with 2 mm preload.
34. Place end measuring plateVW 385/33 on face of pinion gear. [Note: Ensure contact surface of end measuring plate fits exactly and is free of oil.]
35. Detach master gaugeVW 385/30 and insert universal measuring tool in housing.
36. Fit cover for final drive and tighten 4 bolts to 20 Nm. — 20 Nm (15 lb-ft)
37. Using the adjustable ring, pull 2nd centring discVW 385/36 out as far as possible so that the universal measuring tool can still just be turned by hand.
38. Turn universal measuring tool until tip of dial gauge touches end measuring plate on face of pinion gear, and measure maximum deflection (return point). [Note: Then (after removing universal measuring tool), check once again that the dial gauge indicates "“0”" with 2 mm preload when master gaugeVW 385/30 is in place.]
39. Determine shim(s) according to table. For part number, refer to Electronic parts catalogue.
40. Determine shim(s) according to table. For part number, refer to Electronic parts catalogue.
41. Install pinion shaft with appropriate measured shims "“S"3” and "“S"4”.
42. Turn pinion shaft 5 turns in each direction so that tapered roller bearings seat properly.
43. Insert universal measuring tool and check adjustment.
44. Read off dial gauge anti-clockwise (red scale).

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