End Cover, Servicing

End cover, servicing, 01E, 6 Spd. M/T AWD

Special tools and equipment:

^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 412 Thrust tool
^ VW 415 A Tube
^ VW 472/2 Spacer sleeve
^ 2006 A Supporting ring

Special tools and equipment (continued):

^ 1 - Kukko 21/6 Internal puller and Kukko 21/7 Internal puller
^ 4 - Kukko 22/2 Counter support





1 - End cover
^ If replaced, the thickness of the circlip -5- must be re-determined
^ Re-determine shims for Torsen differential

2 - Oil drain plug, 40 Nm
3 - Cylinder roller bearing for input shaft
^ Pressing out go to Fig. 1
^ Pressing in flush go to Fig. 2

4 - Four-point bearing for input shaft
^ Removing go to Fig. 3
^ Installing go to Fig. 4
^ If replaced, the thickness of the circlip -5- must be re-determined





5 - Circlip
^ Re-determining thickness
^ Installing go to Fig. 4

6 - Baffle plate
^ Replace
^ Removing go to Fig. 3
^ Installing and peening in position when replacing four-point bearing for input shaft go to Fig. 5
^ Installing and peening in position when replacing end cover go to Fig. 6

7 - Needle bearing
^ For Torsen differential
^ Pulling out go to Fig. 7
^ Tapping in go to Fig. 8





Fig. 1 Pressing cylinder roller bearing for input shaft out of end cover
A - Internal extractor 37 to 46 mm, e.g. Kukko 21/6
B - Counter support spindle, e.g. Kukko 22/2





Fig. 2 Pressing cylinder roller bearing for input shaft into end cover
Shoulder of pipe section VW 415 A faces toward press tool VW 412.





Fig. 3 Removing ball bearing for input shaft out of end cover
- Position screwdriver as illustrated, drive into baffle plate -arrow- and lever out.
- Remove circlip.
- Take out 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- face toward roller sleeve for drive pinion.

Note: The thickness of the circlip must be re-determined if the bearing or the end cover are replaced.

- Determining thickness of circlip for four-point bearing for input shaft:
- Press outer race of four-point bearing onto stop.
- Determine the thickest circlip that will just fit and install it.
^ Axial play: no more than 0.08 mm

Available circlips









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 peen in position.
- Insert baffle plate.
- First peen at points marked with -arrows 1 -
- Then peen at points marked with -arrows 2- at distance -a- from first position.
^ Distance a = 5 mm

- Observe position and diameter of peening positions:
^ Distance 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 A- from the center line of the two shafts.
^ Dimension d = 10 mm
- Observe position and diameter of peening positions:
^ Distance b = 2 mm
^ Dimension c = 3 mm
- Peen in second and third peening points in same manner at distance -a-.
^ Distance a = 70 mm





Fig. 7 Removing needle bearing for Torsen differential from end cover
A - Internal puller 46 to 58 mm, e.g. Kukko 21/7
B - Spindle from counter support, e.g. Kukko 22/2





Fig. 8 Insert needle bearing of Torsen differential flush in end cover.
- Install pressure plate VW 412 onto bearing with shoulder facing up.