End Cover, Servicing

End cover, servicing
Special tools, testers and auxiliary items required:
^ Thrust plate VW 401
^ Press tool VW 407
^ Press tool VW 412
^ Tube VW415a
^ 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:
- Redetermine thickness of circlip -5-.
- Redetermine shims for Torsen differential, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing and (Assembly Sequence).
2. oil drain plug, 40 Nm
3. Cylinder roller bearing for input shaft
^ Pulling out, Refer to Fig. 1
^ Pressing in flush, Refer to Fig. 2
4. Ball bearing for input shaft
^ Removing, Refer to Fig. 3
^ Installing, Refer to Fig.4
^ If replaced, redetermine thickness of circlip -5
5. Circlip
^ Redetermine thickness
^ Installing, Refer to Fig. 4
6. Baffle plate
^ Replace
^ Removing, Refer to Fig. 3
^ Installing and peening In position when replacing ball bearing for input shaft, Refer to Fig. 5
^ Installing and peening in position when replacing end cover, Refer to Fig. 6
7. Needle - bearing for Torsen differential
^ Pulling out, Refer to Fig. 7
^ Driving in, Refer to Fig. 8





Fig. 1 Pulling 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





Fig. 2 Pressing cylinder roller bearing for input shaft flush into end cover
^ Tube VW 415a with shoulder towards press tool VW 412





Fig. 3 Removing ball bearing for input shaft from end cover
- Position screwdriver as illustrated, drive into baffle plate (arrow) and pry out.
- Remove circlip.
- Takeout bearing, remove peening indentations if necessary.





Fig.4 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 bail 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. Part numbers
Refer to Parts Supplier





The following circlips are available:
- Fit circlip.





Fig. 5 Peening 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 peon 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





Fig. 6 Peening 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 peering post lolls.
^ 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





Fig. 7 Pulling 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





Fig. 8 Driving needle bearing for Torsen differential flush into end cover
- Fit press plate VW 412 onto bearing with shoulder facing up.