Disassembling & Assembling

Disassembling





Special tools, testers and auxiliary items required
^ Sleeve VW 192
^ Holding fixture VW 313
^ Pressure plate VW 401
^ Pressure plate VW 402
^ Punch VW 408A
^ Punch VW 412





Special tools, testers and auxiliary items required
^ Thrust piece VW 432
^ Thrust pad VW 510
^ Slide hammer VW 771
^ Pulling hook VW 771/37
^ Sleeve V.A.G 40-103
^ Tube V.A.G 2010





Special tools, testers and auxiliary items required
^ Thrust piece VAS 2050
^ Thrust piece VAS 3118
^ Drift VAS 3138
^ Alignment fixture VAS 3253
^ Taper roller bearing puller V.A.G 1582/
^ Attachment V.A.G 1582/1





Special tools, testers and auxiliary items required
^ Punch VW 407
^ Driver V.A.G 10-101
^ Torque wrench V.A.G 1601/
^ Transmission holder T10108
^ Alignment fixture T10114
^ 1 Kukko 21/8 Internal puller
^ Torque gauge 0 - 600 Ncm, standard

Drive pinion housing is removed from rear axle housing.





- Set drive pinion housing, as shown in fig. (oil filter = - arrow B -), from below to hole - arrow A - marked with number - 1 - on transmission holder.
- Then align drive pinion housing to remaining 3 holes and secure.





- Remove twelve-point nut for shaft bevel gear.

A - Toggle with 3/4 drive

Note:
^ Secure shaft bevel gear from falling out while removing twelve-point nut.
^ The release moment (break open force) is extremely high, use an extension on toggle if necessary.





- It may be necessary to press off shaft bevel gear from small tapered roller bearing inner race, depending on overlapping (press-fit or loose-fit connection).
- Remove small tapered roller bearing inner race and spacer sleeve.





- Press small tapered roller bearing outer race off drive pinion housing.





- Press large tapered roller bearing outer race - A - off drive pinion housing.

B Internal puller 56 to 70 mm, e.g. Kukko 21/8





- Pull off large tapered roller bearing inner race from shaft bevel gear.
- Clean threads of nut.





- Pull shaft bevel gear seals off drive pinion housing.

Assembling

Note: Clean seats for tapered roller bearing outer races in drive pinion housing of locking fluid.





- Coat outer race for small tapered roller bearing/shaft bevel gear with locking fluid D 154 000 A1 and press into drive pinion housing.





- Coat outer race for large tapered roller bearing/shaft bevel gear with locking fluid D 154 000 A1 and press into drive pinion housing.
- Join new seals for shaft bevel gear as follows:





- Place new seals on each other (- arrows A -), locking lugs - arrows - of seal are offset to each other during this.
- Twist seals on opposite side of sides placed together - arrow B - until locking lugs - arrows - engage into one another, - arrow C -





- Insert combined seals - A - for shaft bevel gear into drive pinion housing.

Installation position:

Seal with smaller outer circumference - arrow - points toward drive pinion housing.





- Drive combined seals for shaft bevel gear into drive pinion housing until stop.





- Press large tapered roller bearing inner race onto shaft bevel gear.
- Coat sealing lips of seals with high performance oil G 052 175 A1 for Haldex clutch.
- Insert shaft bevel gear into drive pinion housing.
- Install new spacer sleeve.





- Press small tapered roller bearing inner race onto shaft bevel gear.

Note: Depending on the overlapping, it may also be possible to slide inner race on shaft bevel gear by hand.

- Secure drive pinion housing to transmission holder T10108.
- Coat threads of twelve-point nut with locking fluid D 154 000 A1.
- Install twelve-point nut for shaft bevel gear.





- Tighten twelve-point nut to 120 Nm, then measure friction torque, increase tightening torque until specified friction torque is set, if necessary.

A - Toggle with 3/4 drive

- Use an adapter of 1/2 on 3/4.

Note: Only increase tightening torque slowly and read off friction torque several times while doing this, if specified friction torque is exceeded, spacer sleeve must be replaced and adjustment must be repeated! A spacer sleeve which has been compressed too much cannot be reused.

Set following frictional torques:





- Measure friction torque.

A - Torque gauge, 0 - 600 Ncm, standard





B - Adapter of 1/2 on 3/4 drive