End Cover, Servicing
End cover, servicing - 6 Spd. Manual Transmission 01E
Special tools, testers and auxiliary items required:
^ Thrust plate VW 401
^ Press tool VW 407
^ Press tool VW 412
^ Tube VW 415a
^ Spacer sleeve VW 472/2
^ Thrust ring 2006A
^ Internal puller 37-46 mm (e.g. Kukko 21/6)
^ Internal puller 46-58 mm (e.g. Kukko 21/7)
^ Counter support (e.g. Kukko 22/2)
1 - End cover
^ If replaced:
- Re-determine thickness of circlip -5-.
- Re-determine shims for Torsen differential.
2 - Oil drain plug, 40 Nm
3 - Cylinder roller bearing for input shaft
4 - Ball bearing for input shaft
^ If replaced, re-determine thickness of circlip -5-
5 - Circlip
^ Re-determine thickness
6 - Baffle plate
^ Replace
^ Install and peen in position when replacing ball bearing for input shaft
^ Install and peen in position when replacing end cover
7 - Needle bearing for Torsen differential
Pull cylinder roller bearing for input shaft out of end cover
A - Internal puller 37-46 mm, e.g. Kukko 21/6
B - Spindle from counter support Kukko 22/2
Press cylinder roller bearing for input shaft flush into end cover
^ Tube VW 415a with shoulder towards press tool VW 412
Remove ball bearing for input shaft from end cover
- Position screwdriver as illustrated, drive into baffle plate (arrow) and pry out.
- Remove circlip.
- Take out bearing, remove peening indentations if necessary.
Installing ball bearing for input shaft in end cover
Installation position of circlip:
^ Ends of circlip (arrows), point towards needle bearing
Note:
The thickness of the circlip must be re-determined if the bearing or the end cover are replaced.
- Determine circlip for input shaft ball bearing:
- Press ball bearing outer race onto stop.
- Determine thickest circlip that can still just be fitted.
Axial play: max. 0.08 mm
- Determine circlip from table.
The following circlips are available:
- Fit circlip.
Peen baffle plate in position when replacing ball bearing for input shaft
- Use a blunt punch with a ball shaped end (ball diameter 5 mm) to peen in position.
- Insert baffle plate.
- Peen at points marked with -arrows 1-.
- Peen at points marked with -arrows 2- at distance -a- from first position.
^ Dimension a = 5 mm
Observe position and diameter of peening positions:
^ Dimension b = 2 mm
^ Dimension c = 3 mm
Peen baffle plate in position when replacing end cover
- Use a blunt punch with a ball shaped end (ball diameter 5 mm) to peen in position.
- Insert baffle plate.
- Peen in first peening point (arrow) at distance -d- from center line of two shafts.
^ Dimension d = 10 mm
- Observe position and diameter of peening positions.
^ Dimension b = 2 mm
^ Dimension c = 3 mm
- Peen in second and third peening points in same manner at distance -a-.
^ Dimension a = 70 mm
Pull needle bearing for Torsen differential out from end cover
A - Internal puller 46-58 mm, e.g. Kukko 21/7
B - Spindle from counter support Kukko 22/2
Driving needle bearing for Torsen differential flush into end cover
- Fit press plate VW 412 onto bearing with shoulder facing up.