Re-determining shim "„S"4“ when renewing gearbox cover — AUDI

🧭 Before you start

Fits: Audi A4 B5 (8D)

• Special tools named: dial gauge

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• The pinion shaft can be rotated by turning both flange shafts together.
• Check that the two dowel sleeves for centralising the gearbox cover are fitted in the gearbox housing.

🔩 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. Thoroughly clean contact surface of housing and bearing seat on old and new gearbox covers.
2. Measure difference in depth (a) on old and new gearbox cover.
3. If new gearbox cover is deeper, install a thicker "„S"4“ shim.
4. If previous gearbox cover is deeper, install a thinner "„S"4“ shim.
5. Press tapered roller bearing outer race with shim "„S"4“ into gearbox cover .

6. Insert completely assembled pinion shaft into gearbox housing again.
7. Fit gearbox cover and tighten bolts to 22 Nm. — 22 Nm (16 lb-ft)
8. Rotate pinion shaft 5 turns in each direction so that the bearing settles. [Note: The pinion shaft can be rotated by turning both flange shafts together.]
9. Set up measuring tools and secure with bolt (arrow) to gearbox housing.
10. Apply dial gauge (3 mm measuring range) onto centre of gearbox cover and set to "„0“" with 2 mm preload.
11. Loosen all gearbox cover bolts approx. one turn.
12. If the correct shims have been selected the dial gauge will now indicate the following value:
13. Detach measuring tools and gearbox cover.
14. Clean sealing surfaces thoroughly for a second time and apply a thin coat of sealing pasteAMV 188 001 02. [Note: Check that the two dowel sleeves for centralising the gearbox cover are fitted in the gearbox housing.]
15. Fit gearbox cover and tighten bolts (1) and (2) to 22 Nm. — 22 Nm (16 lb-ft)

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