Ball bearing in input shaft cover, replacing

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Input shaft cover removed → Torsen differential cover, removing and installing .

Fig 1: Identifying Circlip, Ball Bearing & Input Shaft Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assembly overview

Circlip, measure and always replace
Ball bearing, always replace
Input shaft cover

Removing

Fig 2: Identifying Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove circlip - A -.
Measure and note thickness of removed circlip.

NOTE:

When installing, circlip must be replaced with a new circlip of same thickness.

Fig 3: Laying Input Shaft Cover On Pressure Stand T40099, Placing Under Hydraulic Press & Pressing Ball Bearing With Tube VW 416 B Out Of Input Shaft Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lay input shaft cover - 1 - on pressure stand T40099 and place under hydraulic press.
Press ball bearing with Tube VW 416 B out of input shaft cover.

NOTE:

In some cases, ball bearing can also be pressed out by hand without hydraulic press.
Ball bearing must be replaced.

Installing

Fig 4: Cleaning Cover Sealing Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check cover sealing surface - arrow - and cover for damage:

Surface of sealing surfaces must not show any damage.
Input shaft cover must not be broken cracked.

NOTE:

The illustration is shown with input shaft.

If sealing surface or cover is damaged:

Replace input shaft cover.

NOTE:

A new ball bearing is installed with a new input shaft cover.

If sealing surface and cover are not damaged:

Replace ball bearing.

Fig 5: Identifying Circlip, Ball Bearing & Input Shaft Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clean ball bearing seat in cover - arrow B -.

CAUTION: Note ball bearing position:

The ball bearing cause must face downward in cover.
The open side of the ball bearing must face upward, the balls - arrow A - in the bearing must be visible when inserting.

If the ball bearing is installed incorrectly, it can be damaged during operation and the transmission could possibly be damaged.

Install ball bearing - 2 - flush and press in by hand as far as possible.

Fig 6: Laying Input Shaft Cover On Thrust Plate VW 401 & Using Tube 2010 To Press Ball Bearing In As Far As Stop

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lay input shaft cover on Thrust plate VW 401.
Using a Tube 2010 , press ball bearing in as far as stop.

Fig 7: Identifying Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When installing, circlip - A - must be replaced with a new circlip of same thickness.
Check for correct circlip seating, push ball bearing in or use next thinnest circlip, if necessary.