Audi Workshop Service and Repair Manuals

Servicing end cover

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Spacer sleeve -VW 472/2-

t	Thrust ring -2006 A-

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

Exploded view

1 -

End cover

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

q	Re-determine shims for Torsen differential → Anchor

2 -	Oil drain plug, 40 Nm

3 -	Roller bearing for input shaft

q	Pulling out → Fig.

q	Pressing in flush → Fig.

4 -	Ball bearing for input shaft

q	Removing → Fig.

q	Installing → Fig.

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

5 -

Circlip

q	Re-determining thickness → Anchor

q	Installing → Fig.

6 -	Baffle plate

q

Renew

q	Removing → Fig.

q	Installing and peening in position when renewing ball bearing for input shaft → Fig.

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

7 -	Needle bearing for Torsen differential

q	Pulling out → Fig.

q	Driving in → Fig.

Pulling roller bearing for input shaft out of end cover A -  Internal puller 37 ... 46 mm -Kukko 21/6- B -  Spindle from counter-support -Kukko 22/2-

Pressing roller bearing for input shaft flush into end cover l  The collar of tube -VW 415 A- points towards press tool -VW 412-.

Removing ball 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 ball bearing for input shaft in end cover l  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 renewed. Determining circlip for ball bearing for input shaft –  Press on ball 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) For Part Nos. refer to → Electronic parts catalogue.

–  Fit circlip.

Peening baffle plate in position when renewing ball 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 needle bearing for Torsen differential out of end cover A -  Internal puller 46 ... 58 mm -Kukko 21/7- B -  Spindle from counter-support -Kukko 22/2-

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