Final Drive Cover, Replacing

WARNING: This page is about a different variant/trim than selected.

The adjusting shim used for the differential tapered roller bearing pre-load must be determined again when replacing the final drive cover.

NOTE:

This adjusting shim is located behind the outer race / tapered roller bearing inside the final drive cover.

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
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

-- Turn transmission so that final drive cover faces upward. Drain the transmission fluid if necessary.

-- Remove the right flange shaft by attaching the Puller - Flanged Shaft T10037 to the final drive cover -arrow-.

Fig 1: Identifying Right Flange Shaft By Fastening T10037

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows-.

Fig 2: Locating Final Drive Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Danger of causing damage to the differential.

Slowly and carefully remove front final driver cover from transmission housing. Otherwise differential can fall out of transmission.
A damaged differential may not be installed again. If the differential gets damaged, then the transmission must be replaced.

-- Remove the final drive cover.

-- Carefully pry out the outer race/tapered roller bearing from the old final drive cover by placing the Puller - Grease Cap VW637/2 alternating from side to side and press in direction of -arrow-.

Fig 3: Prying Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Do not remove the outer race/tapered roller bearing with the Puller - Grease Cap VW637/2. Remove the outer race using the Puller - Kukko Internal21/89 -B- and the Puller - Kukko Counterstay22/4 -A-.

Fig 4: Identifying Outer Race Tapered Bearing, Removal

Courtesy of AUDI OF AMERICA, LLC

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

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

-- Remove the old adjusting shim.

Determining the Shim

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

Fig 5: Determining Shim Thickness

Courtesy of AUDI OF AMERICA, LLC

-- Install the Measuring Set - Centering Disk VW385/41 in the bearing seat for the outer race/tapered roller 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	58.40 mm
Dimension -a- for the new final drive cover	58.65 mm
Difference	= 0.25 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	1.50 mm
Difference	- 0.25 mm
New shim	= 1.25 mm

NOTE:

Allocate adjustment shim .

-- In this example, the adjusting shim thickness is 1.25 mm.

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

-- Press the outer race/tapered roller bearing in all the way. The smaller diameter of the Seal Installer - Crankshaft VW204B faces the outer race/tapered roller bearing.

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 Tapered Roller Bearing / Differential as Follows:

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

Fig 7: Checking Tapered Roller Bearing Pre-Load

Courtesy of AUDI OF AMERICA, LLC

-- Install the measuring tools.

-- 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 (3 mm measuring range) with 1 mm preload to >>0<<.

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

-- Read the measured value on the gauge.

It must be 0.10 to 0.15

-- Install the final drive cover with a new O-ring and tighten the bolts -arrows-. Tightening specification 24 Nm.

Fig 8: Locating Final Drive Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Lightly coat the outer circumference of the new shaft seal with oil.

Fig 9: Installing Shaft Seal

Courtesy of AUDI OF AMERICA, LLC

-- Install the new right flange shaft seal all the way without tilting it.

-- Fill the space between the sealing and dust lip halfway with Sealing Grease G 052 128 A1.

-- Always replace the right flange shaft locking ring -A-.

Fig 10: Identifying Circlip

Courtesy of AUDI OF AMERICA, LLC

-- Clamp the flange shaft in a vise with jaw protectors. Remove the old circlip from the groove in the flange shaft using the new circlip -A-.

-- Drive in the right flange shaft using the Bearing/Bushing Installer - Multiple Use VW295.

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