Front final drive cover (on removed transmission), removing and installing

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Fig 1: Identifying Special Tools - Front Final Drive Cover (On Removed Transmission), Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Old oil collecting and extracting device V.A.G 1782
Puller T10037
Drift VW 295

Removing

NOTE:

Front final drive cover, removing and installing on installed transmission → 39 - FINAL DRIVE, DIFFERENTIAL
Observe general repair notes → Repair instructions .
Rules of cleanliness for working on automatic transmissions → Rules for cleanliness when working on transmission .
Transmission removed and secured to assembly stand → Transmission, attaching to assembly stand .

Fig 2: Removing Drive Flange (Left Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
Tightly thread lower support of puller T10037 on front differential cover - arrow -.

NOTE:

To avoid damage to the needle bearings (polygon bearings) or differential during removal, the flange shaft must be removed evenly, parallel and without one sided pressure

Remove left flange shaft with Puller T10037.
Clamp flange shaft in vise, using jaw protectors.

Flange shaft circlip must always be replaced.

Fig 3: Pressing Circlip With New Circlip Out Of Flanged Shaft Groove

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press circlip with new circlip - A - out of flanged shaft groove.

CAUTION: Before removing front final drive cover, ensure that right flange shaft is installed. Otherwise differential can fall out of transmission housing.

Fig 4: Tightening Bolts On Front Final Drive Cover In Sequence 11 To 1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten bolts on front final drive cover - 11 to 1 - in sequence.

CAUTION:

Slowly and carefully remove front final driver cover from transmission housing. Otherwise differential can fall out of transmission.
A differential that has fallen out can no longer be installed. If differential falls out, transmission must be replaced.
Ensure that the differential bearing race and adjustment shims do not fall out of the transmission housing and front final drive cover.
Bearing rings and adjustment shims that have fallen out cannot be relocated with workshop equipment.

Fig 5: Securing Differential Against Falling Out

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure differential - arrow - against falling out.

Installing

Fig 6: Ensuring That Magnet Under Plastic Cover In Front Final Drive Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ensure that magnet under plastic cover in front final drive cover is installed.

Fig 7: Replacing O-Ring In Front Final Drive Cover & Checking Cover For Secure Seating

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace O-ring - 1 - in front final drive cover.
Check cover for secure seating - 2 -.

Fig 8: Checking Differential For Correct Seating In Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check differential - arrow - for correct seating in transmission.

Fig 9: Replacing All Bolts On Front Final Drive Cover & Installing Shield Between Final Drive Cover And Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position front final drive cover on transmission housing.
Replace all bolts on front final drive cover.
If present, install shield - B - between final drive cover and bolt - 1 -.

NOTE:

The shield - B - should protect the bleeder hole - arrow A - from dirt and water.

Fig 10: Tightening Bolts On Front Final Drive Cover In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tightening sequence:

CAUTION:

The 3 bolts with spacer washers are inserted in the places marked with the - arrows -.
Use original bolts .

Tighten bolts on front final drive cover in 2 stages in sequence shown as follows:
Stage: Hand-tighten bolts in - 1 to 11 - sequence.
Stage: Tighten bolts in - 1 to 11 - sequence in several stages to tightening torque.
Check left flange shaft seal, replace if necessary → Left flange shaft seal, replacing

Install left flange shaft → 39 - FINAL DRIVE, DIFFERENTIAL .
Fill axle oil and check level in front final drive → 39 - FINAL DRIVE, DIFFERENTIAL .

CAUTION: The Multitronic 01J or 0AN transmission requires a different axle oil than shift automatics. Only axle oil for Multitronic which can be obtained as a replacement part must be used in front final drive .

Torque specification

Component	Nm
Front final drive cover on transmission housing	25 ¹⁾
Oil filler plug on front final drive cover	20
¹⁾ Replace bolts.