Final Drive Cover
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.
• General repair instructions, refer to => [ Repair Information ] Procedures.
• This adjusting shim is located behind the outer race / tapered roller bearing inside the final drive cover.
Special tools, testers and auxiliary items 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 (T10037)
• 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 ] Procedures.
- Remove right front wheel.
- Remove the rear noise insulation by loosening the fasteners - 2 - and - 3 -
- If equipped, remove the noise insulation - 1 - in the right wheel housing.
- Place the (V.A.G 1782) under the transmission.
- Remove the plug - arrow - and drain the transmission fluid.
- Install the plug - arrow - and tighten it to 40 Nm.
- Remove the bolts - arrows - and remove the heat shield from the right drive axle.
- Remove the right drive axle on the transmission and lay it aside.
- 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 -.
Remove the bolts - arrows - and the final drive cover.
There is a risk of destroying the differential.
• When removing the final drive cover, make sure the differential does not fall out.
- 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.
• 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 -.
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:
- 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:
• Allocate adjustment shim according to the electronic parts catalog ETKA.
- 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.
• Support the final drive cover using the (3345) directly under the bearing mount.
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 -.
- 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 -.
- Install the final drive cover with a new O-ring and tighten the bolts - arrows -.
• Replace right flange shaft seal => [ Installing ] Final Drive, Differential (0B4A Manual Transmission)
- Always replace the right flange shaft circlip - A -.
- 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.
- Install the drive axle heat shield.
- Fill transmission oil and check oil level. Refer to => [ Manual Transmission, Checking Transmission Fluid Level ] Service and Repair.
- If equipped, install the noise insulation - 1 - in the right wheel housing.
- Install the rear noise insulation.
Tightening Specifications
