Final Drive Cover

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

Crankshaft Seal Installing Tool VW 204 B
Needle Bearing Drift VW 295
End Gauge VW 385/33
Centering Disk VW 385/41
Dial Gauge Holder VW 387
Thrust Plate VW 402
Thrust Disc VW 412
Grease Cap Puller VW 637/2
Press Tool 3345
Puller T10037
Ruler T40100

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

-- Remove the right flange shaft by installing the T10037 to the final drive cover -arrow-.

Fig 1: Removing Right Flange Shaft

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.

-- Mount the VW 637/2 alternating from side to side and pressing in direction of -arrow- and then carefully pry out the outer race / tapered roller bearing from the old final drive cover.

Fig 3: Prying Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

NOTE:

If it is not possible to remove the outer race / tapered roller bearing using the VW 637/2, then remove the outer race using the internal puller Kukko 21/89 -B- and the counterholder Kukko 22/4 -A-.

Fig 4: Removing Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

A - Counter-support, for example, Kukko 22/4

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

-- Remove the old adjusting shim.

Determining Shim Thickness

-- 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 centering disk VW 385/41 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 VAS 6087).

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:

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

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

-- Install the outer race/tapered roller bearing all the way. The smaller diameter of the VW 204 B 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 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 VW 387 in the threaded hole in the transmission housing with the bolt -A-.

-- Position the dial gauge extension in the center of the end gauge VW 385/33.

-- Set the dial gauge (3 mm measuring range) with 1 mm pre-load to 0.

-- Loosen the 4 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; refer to item 8 in Figure.

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 half way with sealing grease G 052 128 A1.

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

Fig 10: Identifying Flange Shaft Clamped In Vise And Using New Circlip To Press Old Circlip Out Of Groove In Flange Shaft

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 the right flange shaft in using the VW 295.

-- Fill the transmission fluid in the manual transmission if it was drained earlier and then check the fluid level. Refer to [For engine(s) CAUA] General Information .