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 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-

–  Turn gearbox so that cover for final drive faces upwards (drain off gear oil if necessary).

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

–  Screw out the bolts -arrows-.   Caution Risk of damaging the differential. t  Slowly and carefully detach the cover for the front final drive from the gearbox housing, as otherwise the differential could fall out of the gearbox. t  Never re-install a damaged differential. The gearbox must be replaced if the differential is damaged. –  Detach the cover for the final drive.

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

If the outer race/tapered roller bearing cannot be removed with the hub grease cap puller -VW 637/2-, extract the outer race using the internal puller-B- and the 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. –  Apply a digital depth gauge (e.g. digital depth gauge -VAS 6087-) to the attachment surface and take measurement. 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 must be 0.10...0.15.

–  Then install cover for final drive with new O-ring and tighten bolts -arrows-. Tightening torque → Item.

–  Lightly oil outer circumference of new oil seal. –  Drive in new flange shaft oil seal (right-side) as far as stop; keep seal straight when installing. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.

–  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-. –  If it has been drained off, the gear oil in the manual gearbox must be topped up and the oil level checked → 6-speed manual gearbox 0B3, front-wheel drive; Rep. Gr.34.