Audi Workshop Service and Repair Manuals

Servicing end cover

Special tools and workshop equipment required

t	Drift -VW 295-

t	Adapter -VW 295 A-

t	Thrust plate -VW 401-

t	Press tool -VW 412-

t	Tube -VW 420-

t	Thrust plate -30-205-

t	Press tool -VW 408 A-

t	Installing tool -30-507-

t	Thrust pad -3062-

t	-1-Internal puller -Kukko 21/4-

t	-4-Counter-support -Kukko 22/1-

End cover - exploded view of components

Observe the general repair instructions → Chapter.

1 -

End cover

q	If renewed, re-determine thickness of circlip → Item

2 -	Roller bearing for input shaft

q	Pressing out → Fig.

q	Pressing in flush → Fig.

3 -	Four-point bearing for input shaft

q	Removing → Fig.

q	Installing → Fig.

q	If renewed, re-determine thickness of circlip → Item

4 -

Circlip

q	Re-determining thickness → Anchor

q	Installing → Fig.

5 -	Baffle plate

q

Renew

q	Removing → Fig.

q	Installing and peening in position when renewing four-point bearing for input shaft → Fig.

q	Installing and peening in position when renewing end cover → Fig.

6 -

Circlip

7 -	Roller bearing for pinion shaft

q	Will be damaged during removal

q

Renew

q	Removing → Fig.

q	Driving in → Fig.

q	Installation position → Fig.

8 -

Magnet

q	Drive in, for example with press tool -VW 408 A-

Pressing roller bearing for input shaft out of end cover

Pressing roller bearing for input shaft into end cover –  Fit thrust plate -30-205- on bearing with recess facing up. –  To press in the roller bearing, place thrust pad -3062- under the seating collar for the roller bearing on the end cover.

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.

Installing four-point bearing for input shaft in end cover l  Ends of circlip -arrows- towards roller bearing for pinion shaft.   Note The thickness of the circlip must be re-determined if the bearing or the end cover are renewed. Determining thickness of circlip for four-point bearing for input shaft –  Press on four-point bearing outer race as far as stop. –  Determine the thickest circlip that can still just be fitted. l  Axial play: max. 0.08 mm. –  Select required circlip thickness from following table:

Available circlips - Thickness in mm 1)
2.55	2.65
2.60	2.70
l  1) Part numbers → Parts catalogue.

–  Fit circlip.

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. –  Install baffle plate. –  First peen at points marked with -arrow 1-. –  Then peen at points marked with -arrows 2- at distance -a- from first position. l  Dimension -a- = 5 mm –  Observe position and Ø of peening positions: l  Dimension -b- = 2 mm. l  Dimension -c- = 3 mm.

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. –  Install baffle plate. –  Peen in first peening point -arrow- at distance -d- from the centre line of the two shafts. l  Dimension d = 10 mm. –  Observe position and Ø of peening positions: l  Dimension -b- = 2 mm. l  Dimension -c- = 3 mm. –  Peen in second and third peening points in same manner at distance -a-. l  Dimension -a- = 70 mm

Pulling roller bearing for pinion shaft out of end cover –  Remove circlip. A -  Internal puller 22 ... 28 mm -Kukko 21/4- B -  Counter-support -Kukko 22/1-

Driving roller bearing for pinion shaft into end cover –  Note installation position → Fig..

Installation position of roller bearing for pinion shaft l  Dimension -a- = 98.6 mm