Final Drive Cover, Replacing (Angular Contact Ball Bearing/Efficiency Bearing)

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Special tools and workshop equipment required

Seal Installer - Crankshaft VW204B
Bearing/Bushing Installer - Multiple Use VW295
Measuring Set - End Gauge VW385/33
Measuring Set - Centering Disk VW385/41 for cover with outer race/tapered roller bearing
Dial Gauge Holder VW387
Press Plate VW402
Press Piece - Multiple Use VW412
Puller - Grease Cap VW637/2
Bearing Installer - Wheel Bearing 3345
Puller - Flanged Shaft T10037
Ruler (2 pc.) T40100
Measuring Set - Centering Ring VW385/38 for cover with outer race/angular contact ball bearing
Press Piece - Ring 2006A
Seal Installer - Flange Shaft T40163
Puller - Kukko Internal 21/89
Puller - Kukko Counterstay 22/2
Digital Depth Gauge VAS6087
Dial Gauge for example Dial Gauge - 0-3mm VAS6080
Sealing Grease G 052 128 A1

NOTE:

Depending on the version, different final drive covers are installed.

When replacing the final drive cover the shim for the pre-loading differential must be determined again.

This adjusting shim is located behind the outer race inside the final drive cover.

New version (efficiency bearing) from transmission production date 08/15/2011:

Differential with left tapered roller bearing and right angular contact ball bearing

Transmission removed. Refer to TRANSMISSION, REMOVING AND INSTALLING .

-- Secure the transmission on the transmission holder. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

Fig 1: Securing T40206 To Transmission With Bolts And Tighten It In Assembly Stand

Courtesy of AUDI OF AMERICA, LLC

-- Turn the transmission so that the final drive cover faces upward.

-- Remove the right flange shaft. Refer to RIGHT FLANGE SHAFT, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and the final drive cover.

Fig 2: Locating Final Drive Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

-- First press the angular contact ball bearing outer race slightly out of the bearing seat by installing the Puller - Grease Cap VW637/2 continuously in small steps and press in the -direction of the arrow-.

Fig 3: Prying Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

-- Then pull out the outer race using the Puller - Kukko Internal 21/89 -B- and the Puller - Kukko Counterstay 22/4 -A-

Fig 4: Removing Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

A - Counter Support, for example, Puller - Kukko Counterstay 22/4

B - Internal Puller 56 to 110 mm, for example, Puller - Kukko Internal 21/89

-- Remove the old adjusting shim.

Determining the shim

Fig 5: Measuring Dimension -A- On The Final Drive Cover

Courtesy of AUDI OF AMERICA, LLC

-- Measure the dimension -a- on the old and new covers as follows:

Insert the old shim in the cover, so that the Measuring Set - Centering Ring VW385/38 is accurately placed in the following procedure.

-- Install the Measuring Set - Centering Ring VW385/38 in the bearing seat for the outer race/angular contact ball bearing.

-- Measure the bolting surface with the digital depth gauge (for example Digital Depth Gauge VAS6087).

Example:

Dimension -a- for the old final drive cover	67.45 mm
Dimension -a- for the new final drive cover	67.60 mm
Difference	= 0.15 mm

-- Install a thicker adjusting shim if the dimension -a- on the new cover is smaller.

-- Install a thinner adjusting shim if the dimension -a- on the new cover is larger.

Example:

Old shim	1.30 mm
Difference	- 0.15 mm
New shim	= 1.15 mm

NOTE:

Allocate correct adjustment shim.

-- In this example, the adjusting shim thickness is 1.15 mm.

-- Install the new adjusting shim in the new final drive cover.

-- Press the outer race/angular contact ball bearing in all the way. The larger diameter of the Seal Installer - Crankshaft VW204B faces the outer race.

Fig 6: Installing Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Support the final drive cover using the Bearing Installer - Wheel Bearing 3345 directly under the bearing mount.

Check the bearing pre-load measure for the bearing/differential as follows:

Fig 7: Checking Tapered Roller Bearing Pre-Load

Courtesy of AUDI OF AMERICA, LLC

-- Install the final drive cover without an o-ring and tighten the 4 bolts -arrows-.

-- Remove the measuring tools on the transmission housing.

-- Attach the Dial Gauge Holder VW387 to the threaded hole in the transmission housing with the bolt -A-.

-- Place the Dial Gauge Extension on the center of the Measuring Set - End Gauge VW385/33.

-- Set the Dial Gauge, for example Dial Gauge - 0-3mm VAS6080, to >>0<< with 1 mm of pretension.

-- Loosen the four bolts -arrows- diagonally one turn.

-- Read the measured value on the gauge.

It must be 0.25 to 0.30 on a bearing with less mileage.

NOTE:

For a bearing with higher mileage the measured value must be minimum of 0.05 mm.

-- Replace o-ring -A-.

Fig 8: Identifying O-ring

Courtesy of AUDI OF AMERICA, LLC

-- Insert the final drive cover and tighten the bolts -arrows-, tightening specification -item 12- Bolt (See Figure).

Fig 9: Locating Final Drive Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Install the new flange shaft seal on the right side; refer to RIGHT SEAL, REPLACING .

-- Install the right flange shaft. Refer to REMOVING AND INSTALLING - "Install The Right Flange Shaft".

-- Fill the transmission fluid if it was drained earlier and then check the fluid level. Refer to TRANSMISSION FLUID LEVEL, CHECKING .