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
• Universal Dial Gauge Mount VW 387
• Pressure Plate VW 402
• Thrust Disc VW 412
• Grease Cap Puller VW 637/2
• Press Tool 3345
• Puller T 10037
• Ruler (1 Set = 2 Pieces) T40100
• Use Oil Collecting and Extracting Device V.A.G 1782

• Transmission is installed.

Procedure 

-- General repair instructions, refer to 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: Remove Right Drive Axle Cover

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-- Place the V.A.G 1782 under the transmission.

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

Fig 3: Locating Transmission Fluid Drain Plug

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

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

Fig 4: Driveshaft Heat Shield - Tightening Specification

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

-- Place the V.A.G 1782 under the transmission near the differential.

-- Remove the right flange shaft by installing the T10037 to the final drive cover -arrow-.

Fig 5: Remove right flange shaft by fastening T10037

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

Fig 6: Left Flange Shaft SeaL

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-- 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 7: Prying Outer Race Tapered Bearing

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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 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, 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 9: Determining Shim Thickness

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-- Install the 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.

-- Press in the outer race/tapered roller bearing until you hit the stop and see the smaller diameter of VW 204 B for the outer race/tapered roller bearing.

Fig 10: Installing Outer Race Tapered Bearing

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

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

-- Set the 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 between 0.10 to 0.15 mm

-- 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 SHAFT SEALS ON TRANSMISSION OVERVIEW .

Fig 13: Left Flange Shaft SeaL

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-- Always replace the right flange shaft circlip -A-.

Fig 14: Identifying Flange Shaft Clamped In Vise And Using New Circlip To Press Old Circlip Out Of Groove In Flange Shaft

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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 the right flange shaft in using the VW 295.

-- Attach the drive axle to the flange shaft. Refer to DRIVE AXLE .

-- Install the drive axle heat shield.

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

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

Fig 15: Remove Right Drive Axle Cover

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

Tightening Specifications