Audi Workshop Service and Repair Manuals

Note:

General repair instructions .

• End cover
• ◆ If renewed, re-determine thickness of circlip -item 4-
• Cylinder roller bearing for input shaft
• ◆ Pressing out => Fig.1
• ◆ Pressing in flush => Fig.2
• Four-point bearing for input shaft
• ◆ Removing =>Fig.3
• ◆ Installing =>Fig.4
• ◆ If renewed, re-determine thickness of circlip -item 4-

• Circlip
• ◆ Re-determining thickness
  
• ◆ Installing =>Fig.4
• Baffle plate
• ◆ Always renew
• ◆ Removing =>Fig.3
• ◆ Installing and peening in position when renewing four-point bearing for input shaft => Fig.5
• ◆ Installing and peening in position when replacing end cover => Fig.6
• Circlip

• Roller sleeve for drive pinion
• ◆ Becomes damaged when removed
• ◆ Always renew
• ◆ Removing => Fig. 7
• ◆ Driving in => Fig.8
• ◆ Installation position => Fig. 9
• Magnet
• ◆ Drive in, for example with press tool VW 408 A

→ Fig.1    Pressing cylinder roller bearing for input shaft out of end cover

→ Fig.2    Pressing cylinder roller bearing for input shaft into end cover

• ◆ Place thrust plate 30-205 onto bearing with recessed side facing upwards.

Note:

To press in the cylinder roller bearing, place thrust pad 3062 under the seating collar for the cylinder roller bearing on the end cover.

→ Fig.3    Removing four-point bearing for input shaft from 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 four-point bearing for input shaft in end cover

Installation position of circlip:

• ◆ Ends of circlip -arrows- towards 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 can still just be fitted.
• ‒ Axial play: max. 0.08 mm
• ‒ Determine circlip from table. Part numbers

=> Parts catalogue

Circlips available

• ‒ Fit circlip.

→ Fig.5    Peening baffle plate in position when renewing four-point 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.
• ‒ Dimension a = 5 mm
• ‒ Observe position and diameterof peening positions:
• ‒ Dimension b = 2 mm
• ‒ Dimension c = 3 mm

→ Fig.6    Peening baffle plate in position when renewing 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 the centre line of the 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

→ Fig.7    Pulling roller sleeve for drive pinion out of end cover

• ‒ Remove circlip.

•     A -    Internal puller 22 ... 28 mm, e.g. Kukko 21/4
•     B -    Counterhold, e.g. Kukko 22/1

→ Fig.8    Driving roller sleeve for drive pinion into end cover

• ‒ Note installation position => Fig.9.

→ Fig.9    Installation position of roller sleeve for drive pinion

• ◆ Dimension a = 98.6 mm