Final Drive Cover, Replacing

WARNING: This page is about a different car, the 2024 Audi A4 allroad. However, it is still accessible from the selected car via links, so may be relevant.

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.

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

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 OF AMERICA, LLC
-1- Counter Support (Kukko 22/4):VAS 251 625

Remove the transmission. Refer to TRANSMISSION, REMOVING .

-- 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 OF AMERICA, LLC

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

-- 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 OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove the old shim.

Shim, Determining

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	Courtesy of AUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLC Courtesy of AUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLCAUDI OF AMERICA, LLC Courtesy of AUDI OF AMERICA, LLCAUDI OF 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Allocate adjustment shim according to the 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 OF AMERICA, LLC

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

Courtesy of AUDI OF AMERICA, LLC

-- 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 OF AMERICA, LLC

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

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

-- 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