Final Drive Cover, Replacing

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

NOTE:

General repair instructions. Refer to GENERAL REPAIR INFORMATION .

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 Bearing3345
Puller - Flanged Shaft T10037
Ruler (2 pc.) T40100
Used Oil Collection and Extraction Unit SMN372500

Transmission is installed.

Procedure

-- Follow the general repair instructions. Refer to GENERAL REPAIR INFORMATION .

-- Remove right front wheel.

-- Remove the rear noise insulation by loosening the fasteners -2- and -3-

Fig 1: Identifying Noise Insulation Components

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-- If equipped, remove the noise insulation -1- in the right wheel housing.

Fig 2: Driveshaft Cover -1-

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-- Place the Used Oil Collection and Extraction Unit SMN372500 under the transmission.

Fig 3: Locating Transmission Fluid Drain Plug

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-- Remove the plug -arrow- and drain the transmission fluid.

-- Install the bolt -arrow- and tighten it to 40 Nm.

-- Remove the bolts -arrows- and remove the heat shield from the right drive axle.

Fig 4: Drive Axle Heat Shield & Bolts

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-- Remove the right drive axle on the transmission and lay it aside. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Place the Used Oil Collection and Extraction Unit SMN372500 under the transmission near the differential.

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

Fig 5: Removing Right Flange Shaft

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

Fig 6: Locating Final Drive Cover Bolts

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CAUTION:

There is a risk of destroying the differential.

When removing the final drive cover, make sure the differential does not fall out.

-- 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 7: Prying Outer Race Tapered Bearing

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NOTE:

If the outer race/tapered roller bearing cannot be removed using the Puller - Grease Cap VW637/2, then remove the outer race Internal Puller 56 to 110 mm -B- and the Counter-Support -A-.

Fig 8: Removing Outer Race Tapered Bearing

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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 9: Determining Shim Thickness

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

-- 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 10: Installing Outer Race Tapered Bearing

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NOTE:

Support the final drive cover using the Bearing Installer - Wheel Bearing3345 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 11: Checking Tapered Roller Bearing Pre-Load

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-- 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

-- Replace the O-ring -arrow-.

Fig 12: Differential Cover O-Ring

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-- Install the final drive cover with a new O-ring and tighten the bolts -arrows-. Tightening specification, refer to -item 12- Seal (See Figure).

Fig 13: Locating Final Drive Cover Bolts

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NOTE:

Install the new flange shaft seal on the right side; refer to INSTALLING .

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

Fig 14: Replacing Right Flange Shaft Locking Ring

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-- 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.

-- Attach the drive axle to the flange shaft. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the drive axle heat shield.

-- Fill transmission oil and check oil level. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

-- If equipped, install the noise insulation -1- in the right wheel housing.

Fig 15: Driveshaft Cover -1-

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-- Install the rear noise insulation. Refer to OVERVIEW - NOISE INSULATION .

Tightening Specification

Component	Nm
Heat shield for drive axle to transmission	23