Transmission Cover, Servicing

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Special tools and workshop equipment required

Press Piece - Output Shaft Gear/Final Drive Gear: 3002
Press Piece - Trailing Arm: 2010
Puller - Grease Cap: VW637/2
Drive Sleeve: 30-20
Thrust Piece and Sleeve: VW 472
Press Piece - Multiple Use: VW473
Press Piece - Bushing: 3118
Press Piece - Bushing - 50mm Diameter: VW432
Seal/Bearing Installer - Sleeve: 32-109
Press Piece - Multiple Use: VW412
Seal/Bearing Installer - Multiple Use: 30-21
Slide Hammer Set: VW771
Press Piece - Bushing: VW434
Puller - Two Arm: T10040
Internal Puller (Kukko 21-3): VAS251601
Counter Support: VAS251621
Press Tool: T40323

Output Shaft Cover, Removing

Fig 1: Output Shaft Cover, Removing

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-- Remove the caps, to do so sheer on the center of the cap and remove using the : VW637/2 as shown.

-- Remove the oil catch tray -1-.

Fig 2: NO CONTENT

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Install the Caps for the Output Shaft 1

Fig 3: Install the Caps for the Output Shaft -1-

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-- Press in the new end cover with the : T40323 .

The oil catch tray must be installed

CAUTION:

Oil loss due to improper assembly.

The end cover is installed "dry". Never use retaining compound.
Let the end cover be tensioned 10 minutes with the Press Tool: T40323 .

Remove the pinion roller sleeve 1

Fig 4: Remove the pinion roller sleeve -1-

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Beforehand, remove the circlip for the roller sleeve -item 1- OVERVIEW - TRANSMISSION COVER => List Item: Circlip.

2 - Internal Puller (Kukko 21-3): VAS251601

3 - Counter Support: VAS251621

Tip:

The transmission cover can be attached to the Transmission Support: VW353 for this procedure.

Press in the Pinion Roller Sleeve 1

Fig 5: Press in the Pinion Roller Sleeve -1-

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2 - Press Piece - Multiple Use: VW412

3 - Seal/Bearing Installer - Multiple Use: 30-21

Position the roller sleeve -1- with the lettered side (larger panel thickness) to the Sleeve: 30-21 -3-.

-- Then install the roller sleeve circlip -item 1- OVERVIEW - TRANSMISSION COVER => List Item: Circlip.

Removing the Roller Bearing for the Output Shaft, FWD Vehicles

Fig 6: Removing the Roller Bearing for the Output Shaft, FWD Vehicles

Courtesy of AUDI OF AMERICA, LLC

On FWD vehicles the roller bearing for the output shaft is destroyed when removing and must be replaced.

Beforehand, remove the circlip for the roller sleeve -item 10- OVERVIEW - TRANSMISSION COVER => List Item: Circlip.

-- Position the Slide Hammer Set - Hook: VW771/37 -3- under the bearing cage and mount rolls -2- and drive out the bearing cage from the bearing shell -1-.

3 - Slide Hammer Set - Hook: VW771/37

4 - Slide Hammer Set: VW 771

-- The remove the bearing shell -1-.

Fig 7: NO CONTENT

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2 - Puller - Two Arm - Arm: T10040/1

3 - Puller - Two Arm: T10040

4 - Press Piece - Bushing: VW434

5 - Press Piece - Output Shaft Gear/Final Drive Gear: 3002

Pressing in the Roller Bearing 1 for the Output Shaft, FWD Vehicles

Fig 8: Pressing in the Roller Bearing -1- for the Output Shaft, FWD Vehicles

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-- Support the transmission cover using the Press Piece: VW472/1 -5- directly under the bearing mount.

Position the roller sleeve -1- with the lettered side (larger panel thickness) to the Press Piece - Trailing Arm: 2010 -2-.

2 - Press Piece - Trailing Arm: 2010

3 - Drive Sleeve: 30-20

4 - Press Piece - Multiple Use: VW412

-- Then install the roller sleeve circlip -item 10- OVERVIEW - TRANSMISSION COVER => List Item: Circlip.

Driving Out the Roller Sleeve for the Output Shaft 1, AWD Vehicles

Fig 9: Driving Out the Roller Sleeve for the Output Shaft -1-, AWD Vehicles

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-- If equipped, remove the seal for the transmission output shaft. Refer to TRANSMISSION OUTPUT SHAFT SEAL, REPLACING .

Beforehand, remove the circlip for the roller sleeve -item 10- OVERVIEW - TRANSMISSION COVER => List Item: Circlip.

2 - Press Piece - Multiple Use: VW473

Tip:

The transmission cover can be attached to the Transmission Support: VW353 for this procedure.

Pressing in the Output Shaft Roller Sleeve, AWD Vehicles

Fig 10: Pressing in the Output Shaft Roller Sleeve, AWD Vehicles

Courtesy of AUDI OF AMERICA, LLC

Position the roller sleeve with the labeled side (larger panel thickness) to the Press Piece - Bushing: 3118 -1-.

1 - Press Piece - Bushing: 3118

2 - Press Piece - Bushing - 50mm Diameter: VW432

3 - Drive Sleeve: 30-20

4 - Press Piece - Multiple Use: VW412

-- Then install the roller sleeve circlip -item 10- OVERVIEW - TRANSMISSION COVER => List Item: Circlip.

-- If equipped, install the seal for the transmission output shaft. Refer to TRANSMISSION OUTPUT SHAFT SEAL, REPLACING .

Drive Out the Input Shaft Ball Bearing 1

Fig 11: Drive Out the Input Shaft Ball Bearing -1-

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2 - Seal/Bearing Installer - Sleeve: 32-109

Beforehand, remove the ball bearing circlip -item 8- OVERVIEW - TRANSMISSION COVER => List Item: Circlip

Tip:

The transmission cover can be attached to the Transmission Support: VW353 for this procedure.

Pressing in the Input Shaft Ball Bearing 1

Fig 12: Pressing in the Input Shaft Ball Bearing -1-

Courtesy of AUDI OF AMERICA, LLC

Ball bearing installation position: the groove -arrow- all around on the ball bearing points downward to the transmission cover.

2 - Seal/Bearing Installer - Sleeve: 32-109

3 - Drive Sleeve: 30-20

4 - Press Piece - Multiple Use: VW412

Install the Ball Bearing Circlip 2 on the Drive Axle 1

Fig 13: Install the Ball Bearing Circlip -2- on the Drive Axle -1-

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The bevel on the circlip -2- faces away from the ball bearing -1-. The flat side faces the ball bearing.