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.
• 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 Disk (VW 385/41)
• Dial Gauge Holder (VW 387)
• Thrust Plate (VW 402)
• Thrust Disc (VW 412)
• Grease Cap Puller (VW 637/2)
• Press Tool (3345)
• Puller (T10037)
• Ruler (T40100)
- Turn the transmission so that final drive cover faces upward. Drain the transmission fluid if necessary.
- Remove the right flange shaft by installing the (T10037) to the final drive cover - arrow -.
- Remove the bolts - arrows -.
Danger of causing damage to the differential.
• Slowly and carefully remove front final driver cover from transmission housing. Otherwise differential can fall out of transmission.
• A damaged differential may not be installed again. If the differential gets damaged, then the transmission must be replaced.
- Remove the final drive cover.
- 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 (Kukko 21/89) - B - and the counterholder (Kukko 22/4) - 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 centering disk (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.
- Install the outer race/tapered roller bearing all the way. The smaller diameter of the (VW 204 B) faces 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 -.
- Position the dial gauge extension in the center of the end gauge (VW 385/33).
- Set the dial gauge (3 mm measuring range) with 1 mm pre-load to 0.
- Loosen the 4 bolts - arrows - diagonally one turn.
- Read the measured value on the gauge.
• It must be 0.10 to 0.15
- Install the final drive cover with a new O-ring and tighten the bolts - arrows -. Tightening specification; refer to => [ (Item 8) Bolt ] Differential Overview.
- Lightly coat the outer circumference of the new shaft seal with oil.
- Install the new right flange shaft seal all the way without tilting it.
- Fill the space between the sealing and dust lip half way with sealing grease (G 052 128 A1).
- Always replace the right flange shaft locking ring - 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).
- Fill the transmission fluid in the manual transmission if it was drained earlier and then check the fluid level.