Repairing end cover — VW

VW
Phaeton
2003
Power transmission
6-speed manual gearbox 01E, 0A1
Edition
04.2004
Repairing end cover
Special tools and workshop equipment required
Drift
VW 295
Adapter
VW 295a
Pressure plate
VW 401
Press tool
VW 412
Tube
VW 420
Thrust plate
30-205
Press tool
VW 408 A
Press tool
30-507
Thrust pad
3062
1
Internal puller
Kukko 21/4
4
Counterhold
Kukko 22/1
End cover
If renewed, redetermine thickness of retaining ring
Item
.
An end cover with a plug might be fitted in some gearboxes
Fig.
.
Cylindrical roller bearing for input shaft
Pressing out
Fig.
.
Pressing in flush
Fig.
.
Four-point bearing for input shaft
Removing
Fig.
.
Installing
Fig.
.
If renewed, redetermine thickness of retaining ring
Item
.
Retaining ring
Redetermining thickness
Anchor
.
Installing
Fig.
.
Baffle plate
Always renew.
Removing
Fig.
.
Installing and peening in position when renewing four-point bearing for input shaft
Fig.
.
Installing and peening in position when replacing end cover
Fig.
.
Retaining ring
Roller bearing for pinion shaft
Will be damaged when removed.
Always renew.
Pulling out
Fig.
.
Driving in
Fig.
.
Installation position
Fig.
.
Magnet
When replaced, old magnet is destroyed.
Drive in new magnet with e.g.
press tool
VW 408 A
.
Pressing cylindrical roller bearing for input shaft out of end cover
Pressing cylindrical roller bearing for input shaft into end cover
Place
thrust plate
30-205
onto bearing with recess facing upwards.
Note
To press in cylindrical roller bearing, place
thrust pad
3062
under seating collar for cylindrical roller bearing on 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 retaining ring.
Remove bearing, remove peening indentations if necessary.
Installing four-point bearing for input shaft in end cover
Installation position of retaining ring:
Ends of retaining ring
arrows
face roller bearing for pinion shaft.
Note
The thickness of the retaining ring must be redetermined if the bearing or the end cover are replaced.
Determining thickness of retaining ring for four-point bearing for input shaft
Press outer race of four-point bearing on to stop.
Determine thickest retaining ring which will still fit and install it.
Axial play: max. 0.08 mm
Allocate retaining ring with
Electronic parts catalogue
.
Retaining rings available
Retaining ring thickness (mm)
2.55
2.65
2.60
2.70
Fit retaining ring.
Peening baffle plate in position when renewing four-point bearing for input shaft
Use a blunt punch with a ball-shaped end (ball 5 mm ∅) to peen in position.
Insert baffle plate.
First peen at points marked with
arrows 1
.
Then peen at points marked with
arrows 2
at distance
a
from first position.
Dimension a = 5 mm
Observe position and diameter of peening points:
Dimension b = 2 mm
Dimension c = 3 mm
Peening baffle plate in position when renewing end cover
Use a blunt punch with a ball-shaped end (ball 5 mm ∅) to peen in position.
Insert baffle plate.
Locate first peening point
arrow
at distance
d
from centre line of the two shafts.
Dimension d = 10 mm
Observe position and diameter of peening points:
Dimension b = 2 mm
Dimension c = 3 mm
Locate second and third peening points in same manner at distance
a
.
Dimension a = 70 mm
Pulling roller bearing for pinion shaft out of end cover
Remove retaining ring.
A
Internal puller, 22...28 mm
, e.g.
Kukko 21/4
B
Counter support
, e.g.
Kukko 22/1
Driving roller bearing for pinion shaft into end cover
Note installation position
Fig.
.
Installation position of roller bearing for pinion shaft
Dimension a = 98.6 mm
End cover with plug and seal
arrow
On some gearboxes, the end cover is fitted with a plug
arrow
and seal.
The torque setting for the plug is 30 Nm.
Replacement end covers are supplied without plugs.