Re-determining shim "„S4“" when renewing gearbox cover — AUDI

🧭 Before you start

Fits: Audi A4 B5 (8D)

• Special tools named: dial gauge

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• 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. Re-fit fully assembled pinion shaft with hollow shaft into gearbox housing.
7. Fit gearbox cover and tighten bolts to 22 Nm. — 22 Nm (16 lb-ft)
8. To settle the tapered roller bearings: rotate pinion shaft together with hollow shaft 5 turns in each direction, then rotate pinion shaft separately in relation to hollow shaft 5 turns in each direction.
9. Set up measuring tools and secure with bolt (arrow) to gearbox housing.
10. Set dial gauge (3 mm measuring range) 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. [Note: Check that the two dowel sleeves for centralising the gearbox cover are fitted in the gearbox housing.]
14. Clean sealing surfaces thoroughly for a second time and apply a thin coat of sealing pasteAMV 188 001 02.
15. Fit gearbox cover and tighten bolts to 22 Nm. — 22 Nm (16 lb-ft)

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