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.

Special tools and workshop equipment required 

• Crankshaft Seal Installing Tool VW 204 B
• Needle Bearing Drift VW 295
• End Gauge VW 385/33
• Centering Plate 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 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 By Fastening T10037

Courtesy of AUDI OF AMERICA, LLC

-- Remove bolts -arrows-.

Fig 2: Locating Final Drive Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

-- 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 counter holder Kukko 22/4 -A-.

Fig 4: Removing Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

A - 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 plate 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:

-- 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:

-- 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 VW 204 B faces the outer race / tapered roller bearing.

Fig 6: Installing Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

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-.

-- Install measuring tools.

Fig 7: Checking Tapered Roller Bearing Pre-Load

Courtesy of AUDI OF AMERICA, LLC

-- Attach the VW 387 in the threaded hole in the transmission housing with the screw -A-.

-- Place dial gauge extension on center of VW 385/33.

-- Set dial gauge (3 mm measuring range) to 0 with 1 mm preload.

-- 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 -8- DIFFERENTIAL ASSEMBLY OVERVIEW .

Fig 8: Locating Final Drive Cover Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Lightly oil outer circumference of new shaft seal.

Fig 9: Identifying Shaft Seal

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

-- Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

-- Always replace the right flange shaft circlip -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 flange shaft in vise, using jaw protectors. Press circlip with new circlip -A- out of flanged shaft groove.

-- Drive the right flange shaft in using the VW 295.

-- Fill the transmission fluid it was drained earlier and then check the fluid level. Refer to General Information .