Final Drive Cover, Replacing

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When replacing the final drive cover the shim for the pre-loading differential must be determined again.
This shim is located behind the outer race / angular contact ball bearing inside the final drive cover.

Courtesy of AUDI

Special tools and workshop equipment required

Seal Installer - Crankshaft:VW 204 B
Measuring Set - End Gauge:VW 385/33
Dial Indicator Holder:VW 387
Press Plate:VW 402
Press Piece - Multiple Use:VW 412
Bearing Installer - Wheel Bearing:3345

Courtesy of AUDI

Special tools and workshop equipment required

Puller - Grease Cap:VW 637/2
Ruler (2 pc.):T40100
Caliper:T40101
Dial Indicator:VAS 6080A
Digital Depth Gauge such as Digital Depth Gauge:VAS 6087
Hot Air Blower:V.A.G 1416 or Wiring Harness Repair Set - Hot Air Blower: VAS 1978/14A

Special tools and workshop equipment required

-4- Internal Puller (Kukko 21/89):VAS 251 619

Fig 1: Identifying Kukko Puller
Courtesy of AUDI
-1- Counter Support (Kukko 22/4):VAS 251 625

Remove the transmission. Refer to the appropriate Service Information. .

-- Secure the transmission on the transmission holder. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

-- Turn the transmission so that the final drive cover faces upward.

-- Remove the right flange shaft. Refer to RIGHT FLANGE SHAFT, REMOVING AND INSTALLING .

-- Remove the seal -arrow- for the right flange shaft using an extractor lever.

Fig 2: Pry Out Flange Shaft Sealing Ring

Courtesy of AUDI

-- Remove the bolts -arrows- and remove the final drive cover -1-.

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-- Warm the final drive cover to approximately 100 °C (212 °F) with the Hot Air Blower so that the outer race for the angular contact ball bearing can be more easily removed.

-- Then press the angular contact ball bearing outer race slightly out of the bearing seat by gradually installing the Puller - Grease Cap:VW 637/2 in small steps and pressing in the -direction of the arrow-.

Fig 3: Prying Outer Race Tapered Bearing

Courtesy of AUDI

-- Then remove the angular contact ball bearing outer race -3- using the Internal Puller -2- and the Counter Support -1-.

Fig 4: Angular Contact Ball Bearing Outer Race -3-, Removing from Final Drive Cover

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Counter Support (Kukko 22/4):VAS 251 625
Internal Puller (Kukko 21/89):VAS 251 619

-- Remove the old shim.

Shim, Determining

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

-- Position the Caliper (4 pc.):T40101 on the opposite sides of the bolting surface for the final drive cover.

-- Place the Ruler (2 pc.):T40100 upright on these Calipers.

-- Use digital depth dimension (such as Digital Depth Gauge:VAS 6087 ) to measure in the bearing seat for the outer race/angular contact ball bearing.

Example:

Dimension -a- for the old final drive cover	82.05 mm
Dimension -a- for the new final drive cover	82.20 mm
Difference	= 0.15 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	1.30 mm
Difference	- 0.15 mm
New shim	= 1.15 mm

Allocate adjustment shim according to the appropriate Electronic Parts Information.

-- In this example, the adjusting shim thickness is 1.15 mm.

-- Install the new adjusting shim in the new final drive cover.

-- Press in the outer race/angular contact ball bearing all the way, at the same time the larger diameter of the Seal Installer - Crankshaft:VW204B points to the outer race.

Fig 5: Identifying Outer Race Tapered Bearing, Installation

Courtesy of AUDI

Support the final drive cover by supporting the Bearing Installer - Wheel Bearing:3345 directly under the bearing mount.

Check the bearing pre-load measure for the bearing / differential as follows:

Fig 6: Checking Tapered Roller Bearing Pre-Load

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-- Install the final drive cover without an O-ring and tighten the four bolts -arrows-.

-- Remove the measuring tools on the transmission housing.

-- Attach the Dial Gauge Holder:VW 387 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:VW 385/33 .

-- Set the Dial Gauge, for example Dial Gauge - 0-3mm: VAS 6080 , to >>0<< with 1 mm of pretension.

-- Loosen the four bolts -arrows- diagonally one turn.

-- Read the measured value on the dial gauge.

It must be 0.25 to 0.30 mm for bearings with less mileage.
For bearings with higher mileage, the measured value must be a minimum of 0.05 mm.

-- Replace the O-ring -A-.

Fig 7: Identifying Final Drive Cover O-ring

Courtesy of AUDI

-- Coat the new O-ring with transmission fluid.

-- Insert the final drive cover -1- and tighten the bolts -arrows- to the tightening specification.

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-- Install the new right flange shaft seal. Refer to RIGHT SEAL, REPLACING .

-- Install the right flange shaft. Refer to RIGHT FLANGE SHAFT, REMOVING AND INSTALLING .

-- If the transmission fluid is drained, the transmission fluid in the manual transmission must be filled and the fluid level must be checked. Refer to Transmission Fluid .

Tightening Specifications

Refer to OVERVIEW - FINAL DRIVE