Audi Workshop Service and Repair Manuals

Renewing cover for final drive l  When renewing cover for final drive, determine thickness of new shim to adjust preload of tapered roller bearings for differential.   Note t  General repair instructions → Chapter. t  This shim is located behind the tapered roller bearing outer race in the cover for the final drive.

Special tools and workshop equipment required

t	Crankshaft seal installing tool -VW 204 B-

t	Drift -VW 295-

t	Measuring plate -VW 385/33-

t	Centring disc -VW 385/41-

t	Universal dial gauge bracket -VW 387-

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Hub grease cap puller -VW 637/2-

t	Wheel bearing tube -3345-

t	Puller -T10037-

t	Ruler -T40100-

t  Used oil collection and extraction unit -V.A.G 1782- l  Gearbox is installed. Procedure –  Refer to general repair instructions → Chapter. –  Remove front right wheel.

–  Remove rear noise insulation (loosen fasteners -2- and -3-).

–  If fitted, remove noise insulation -1- from wheel housing (right-side).

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Unscrew plug -arrow- and drain off gear oil. –  Screw plug -arrow- back in and tighten to 40 Nm.

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side). –  Detach drive shaft (right-side) from gearbox and place to one side → Rep. gr.40. –  Place used oil collection and extraction unit -V.A.G 1782- underneath gearbox below differential.

–  Remove flange shaft (right-side); to do so, secure puller -T10037- to cover for final drive -arrow-.

Unscrew bolts -arrows- and detach cover for final drive.   Caution Take care not to damage differential. Make sure differential does not drop out when cover for final drive is removed.

–  Carefully prise tapered roller bearing outer race out of old cover for final drive; to do so apply hub grease cap puller -VW 637/2- on alternate sides and press in direction of -arrow-.   Note

If the tapered roller bearing outer race cannot be removed with the hub grease cap puller -VW 637/2-, use internal puller 56 … 110 mm-B- and counter-support-A-. A -  Counter-support, e.g. -Kukko 22/4- B -  Internal puller 56 ... 110 mm, e.g. -Kukko 21/89- –  Remove existing shim.

Determining thickness of shim –  Measure dimension -a- on old cover and new cover as follows: –  Insert centring disc -VW 385/41- in bearing seat for tapered roller bearing outer race. –  Using digital depth gauge (e.g. digital depth gauge -VAS 6087-), measure down to joint flange. Example:

Dimension -a- on old cover for final drive	58.40 mm
Dimension -a- on new cover for final drive	58.65 mm
Difference	= 0.25 mm

–  Install thicker shim if dimension -a- is smaller on new cover. –  Install thinner shim if dimension -a- is greater on new cover. Example:

Existing shim	1.50 mm
Difference	– 0.25 mm
New shim	= 1.25 mm

Note Select correct shim from → Electronic parts catalogue. –  The shim thickness in this example is 1.25 mm. –  Install new shim of required thickness in new cover for final drive.

–  Press in tapered roller bearing outer race as far as stop; smaller Ø of -VW 204 B- goes towards tapered roller bearing outer race.   Note Support cover for final drive with -3345- directly below bearing seat. Check adjustment of preload of tapered roller bearings for differential as follows:

–  Fit cover for final drive without O-ring and tighten 4 bolts -arrows-. –  Attach measuring equipment. –  Secure universal dial gauge bracket -VW 387- to threaded hole in gearbox housing with bolt -A-. –  Apply dial gauge extension to centre of measuring plate -VW 385/33-. –  Set dial gauge (3 mm measuring range) to »0« with 1 mm preload. –  Slacken 4 bolts -arrows- by one turn in diagonal sequence. –  Check reading on dial gauge. l  It should be 0.10 ... 0.15 mm.

–  Renew O-ring -arrow-.

–  Then install cover for final drive with new O-ring and tighten bolts -arrows-; tightening torque → Item.   Note Installing new flange shaft oil seal (right-side) → Anchor

–  Always renew circlip -A- for flange shaft (right-side). –  Clamp flange shaft in vice, using jaw protectors. Use new circlip -A- to press old circlip out of groove in flange shaft. –  Drive in flange shaft (right-side) with drift -VW 295-. –  Bolt drive shaft to flange shaft → Rep. gr.40. –  Fit drive shaft heat shield. –  Fill up with gear oil and check gear oil level → Chapter.

–  If fitted, install noise insulation -1- in wheel housing (right-side). –  Install rear noise insulation → Rep. gr.66. –  Fit front wheel → Rep. gr.44. Tightening torque

Component	Nm
Heat shield for drive shaft to gearbox	23