Final Drive Cover, Replacing

WARNING: This page is about a different car, the 2013 Audi S4, 2012 Audi S4, 2011 Audi S4, and 2010 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

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 .