Final Drive Cover, Replacing: Procedure

-- Secure the transmission to the transmission holder. Refer to TRANSMISSION, SECURING TO ENGINE/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.

-- 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-.

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

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

-- Remove the old shim.

Shim, Determining

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

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-- 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.

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.

Old shim	1.30 mm
Difference	- 0.15 mm
New shim	= 1.15 mm

-- 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.

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

Bearing pre-load measurement check, performing

-- 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 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.

Conditions

• 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.

Finishing procedures

-- Replace the O-ring -A-.

-- 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 flange shaft seal on the right side. Refer to Right Seal, Replacing  .

-- Install the right flange shaft. Refer to Right Flange Shaft, Removing and Installing  .

-- If drained, add transmission fluid. Refer to Transmission Fluid, Draining and Filling .