End Cover, Servicing

End cover, servicing





Special tools and equipment
^ VW 401 Thrust plate
^ VW 407 Press tool
^ VW 412 Press tool
^ VW 415A Tube
^ VW 472/2 Spacer sleeve
^ 2006A Thrust ring

Special tools and equipment





^ VAG 1331 Torque wrench





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





1. End cover
2. Oil drain plug
3. Cylindrical roller bearing for input shaft
^ Pressing out; Refer to Fig 1
^ Pressing in flush; Refer to Fig 2
4. Four-point bearing for input shaft
^ Removing; Refer to Fig 3
^ Installing; Refer to Fig 4
^ When replaced, thickness of circlip item - 5 must be redetermined
5. Circlip
6. Baffle ring
^ Installing and peening following replacement of end cover; Refer to Fig 6
7. Needle roller bearing





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

A - Internal extractor 37 - 46 mm, e g. Kukko 21/6
B - Spindle from counter support, e g. Kukko 22/2





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

Collar of tube VW 415A faces press tool VW 412.





Fig. 3 Removing 4-point bearing for input shaft from end cover

- Apply screwdriver as shown in figure, drive into baffle ring (arrow) and pry out.
- Remove circlip.
- Take out bearing and, if necessary, file away dents from peening.





Fig. 4 Installing 4-point bearing for input shaft in end cover

Installed position of circlip:
Ends of circlip (arrows) face pinion shaft needle roller bearing.

Note: If bearing or end cover is replaced, thickness of circlip must be redetermined.

To determine circlip for 4-point bearing for input shaft:
- Press outer race of 4-point bearing onto stop.
- Determine thickest circlip which can still just be inserted and install.
Axial clearance: max. 0.08 mm

Note: Determine shims according to parts Supplier.





Available circlips

- Install circlip.





Fig. 5 Peening baffle ring when replacing 4-point bearing for input shaft

Note: To peen, use a blunt center punch with a ball-shaped end (ball diameter 5 mm).

- Insert baffle ring.
- Do initial peening (arrows-1-).
- Do second peening (arrows -2-) at distance -a- from initial peening.
Dimension a = 5 mm
- Observe position and diameter of peening points (inset in illustration):
Dimension b = 2 mm
Dimension c = 3 mm





Fig. 6 Peening baffle ring when replacing end cover

Note: To peen, use a blunt center punch with a ball-shaped end (ball diameter 5 mm).

- Insert baffle ring.
- Do first peening at a point (arrow) at distance -d- from a line passing through center of shafts.
Dimension d = 10 mm
- Observe position and diameter of peening points (inset in illustration):
Dimension b = 2 mm
Dimension c = 3 mm
- Locate second and third peening points.
Dimension a = 70 mm





Fig. 7 Pulling Torsen differential needle roller bearing out of end cover

B - Internal puller 46 - 58 mm, e g. Kukko 21/7
B - Spindle from counter support, e g. Kukko 22/2





Fig. 8 Driving Torsen differential needle roller bearing flush into end cover

- Set press tool VW 412 on bearing with collar facing up.