Replacing Differential Housing Cover

Replacing [1][2]differential housing cover

Preparations




Collect the transmission fluid.
Remove the dipstick from the dip stick pipe.
Extract the oil (approximately 6 liters). Use an oil suction unit.

Raise the car. Remove the splash guard under the engine






Remove the right-hand drive shaft
See Drive shaft right, replacing Drive Shaft Right, Replacing.

Remove the vehicle speed sensor (VSS) from the [1][2]differential housing cover




Remove the screw for the splash guard. Press up the deflector plate slightly so that the sensor is accessible.
Place a container underneath the transmission.

Remove:
- the screw holding the sensor
- the sensor.

Remove the bracket between the transmission and the engine





Remove:
- the two screws in the [1][2]differential housing cover
- the three screws for the bracket in the cylinder block
- the bracket.

Remove the [1][2]differential housing cover





Remove:
- the remaining two screws
- the cover.

Note! Remove the throw-out bearing from the [1][2]differential or the cover if it is still in place.

Check the bearing surface for the [1][2]differential




There must not be any visible scratches or abnormal wear on the bearing surface.

Install the spacer washer and the throw-out bearing on the [1][2]differential




Apply a little petroleum jelly on the throw-out bearing so that it secures against the spacer washer.

Install:
- the spacer washer against the gear wheel
- the throw-out bearing, see the illustration.

Install the [1][2]differential housing cover




Use a new gasket.
Finger-tighten the screws.

Install the bracket on the cylinder block





Install:
- the three screws for the bracket for the [1][2]differential housing cover
- the two screws in the [1][2]differential housing cover.
Tighten all the screws in the [1][2]differential housing cover. Tighten to 50 Nm.
Tighten the bracket screws. Tighten to 50 Nm.

Note! There axial clearance must be 0.12 mm - 0.67 mm between the [1][2]differential and the differential housing cover.

Install the vehicle speed sensor (VSS)




Tighten the screw. Tighten to 10 Nm.
Install the screw for the splash guard. Tighten the screw. Tighten to 25 Nm.

Install the right drive shaft
See Drive shaft right, replacing Drive Shaft Right, Replacing.

Finishing work

Install the right wheel
See Installing wheels Service and Repair.

Fill the transmission with oil
Measure the amount of oil that was drained. Fill with the same amount of new oil.

Check the oil level
°
The oil level must be checked at a temperature of 80C. This is to ensure that the read out is correct

Preparations:
- park the car on a level surface
- apply the parking brake
- let the engine idle
- move the gear selector lever to position P
- move the gear selector to each position. Stop for five seconds in each position
- move the gear selector lever to position P. Wait two minutes before checking the level.

Note! Wait two minutes before checking the level.

Note! Cars with Geartronic gear selector assemblies: P-R-N-D-Man. Do not shift up in the manual positions. Cars with conventional gear selector assemblies: P-R-N-D-3-2-1, stop for five seconds in each position.

Oil level / temperature




Maximum level hot 80°C.
Maximum level cold 40°C.
Minimum level hot 80°C.
Minimum level cold 40°C.

Check that there is no oil leakage at the [1][2]differential housing cover

Install the splashguard under the engine
Tighten the screws. Tighten to 25 Nm.