Drive Pinion, Removing and Installing and Disassembling and Assembling
Drive pinion, removing and installing and disassembling and assembling
Special tools and workshop equipment required
^ VW 391 Puller
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Punch
^ VW 408 A Punch
^ VW 412 Thrust disc
Special tools and workshop equipment required
^ VW 457 Supporting channels
^ VW 460 Removal device
^ VW 470/1 Assembly ring
^ VW 519 Sleeve
^ VW 540 Holding fixture
^ 30-205 Thrust pad
Special tools and workshop equipment required
^ 2003/3 Inserter ring
^ 3005 Thrust pad
^ 3028 Retainer
^ 3062 Thrust pad
^ 3138 Drift
^ 3143 Seal driver-Frt wheel bearing
Special tools and workshop equipment required
^ VW 771 Slide hammer-complete set
^ 3026 Mandrel
^ 3253 Wheel bearing assembly set
^ V.A.G 1383 A Engine/transmission jack
Note:
^ Replace both taper roller bearings together.
^ Install new taper roller bearings in delivery condition and do not oil additionally.
^ When replacing the parts marked with 1) adjustment work is required.
1 - Nut
^ Unscrewing see Fig. 1
^ Screwing in see Fig. 15
^ Measuring friction torque see Fig. 16
^ Securing see Fig. 17
2 - Flange for drive shaft
^ Pulling off see Fig. 2
^ Installing see Fig. 14
3 - Sealing ring
^ Pulling out see Fig. 3
^ Tapping in see Fig. 13
4 - O-ring
^ Replace
^ Insert with gear oil see Fig. 12
5 - Inner race for small taper roller bearing 1)
^ Pressing out drive pinion see Fig. 4
^ Pressing on see Fig. 11
6 - Outer race for small taper roller bearing 1)
^ Pulling out see Fig. 5
^ Pressing in see Fig. 10
7 - Spacer sleeve 1)
^ Replace
8 - Final drive housing 1)
9 - Shim "S3"
^ Note thickness
10 - Outer race for large taper roller bearing 1)
^ Tapping out see Fig. 6
^ Inserting see Fig. 9
11 - Inner race for large taper roller bearing 1)
^ Pressing off see Fig. 7
^ Pressing on see Fig. 8
12 - Drive pinion 1)
^ Is mated with ring gear, replace together as a set
Fig. 1 Removing nut for drive pinion
- Secure final drive on a repair stand.
- Screw in two hexagon nuts M8 x 30 -A-.
B - Socket, long A/F 36
- When nut is loosened the final drive must be supported (e.g. with universal transmission mounting 1359/2 in conjunction with engine/transmission jack VAG 1383 A).
Fig. 2 Pulling flange for drive shaft off drive pinion
- Screw two hex nuts M8 x 30 -A- into the flange.
Fig. 3 Pulling out seal for flange for drive shaft
Fig. 4 Pressing drive pinion out of inner race for small taper roller bearing
Fig. 5 Pulling out small taper roller bearing outer race
B - Support, e.g. Kukko 22/2
B - Internal puller 46 to 2.28 in, e.g. Kukko 21/7
Fig. 6 Driving out outer race for large taper roller bearing
- After removing check shims for damage.
Fig. 7 Pressing inner race for large taper roller bearing off drive pinion
A - Separating device 22 to 4.53 in, e.g. Kukko 17/2
Fig. 8 Pressing inner race for large taper roller bearing onto drive pinion
- Heat inner race to approx. 100° C, position and push to final position.
WARNING!
Wear protective gloves!
Fig. 9 Pulling in outer race for large taper roller bearing
- Lightly lubricate bearing seat in housing.
- Insert predetermined shim "S3" for drive pinion.
The inscription "top" on pressure plate 3253/4 faces nut of insertion device
Fig. 10 Pressing in small taper roller bearing outer race
- Lightly lubricate the bearing seat in the housing.
- The outer race must be attached with needle bearing drift VW 295 and thrust pad 30-205.
Fig. 11 Pressing on small taper roller bearing inner race
- Insert new drive pinion with a new spacer sleeve.
WARNING!
Wear protective gloves!
- Heat inner race for small taper roller bearing to approx. 100° C and install onto drive pinion.
- Press up drive pinion and insert bearing with sleeve 40-21 onto stop.
Fig. 12 Inserting O-ring
- Insert O-ring with gear oil.
Fig. 13 Tapping in seal for flange for drive shaft
- Lightly oil outer circumference of seal.
- Drive in seal onto stop with Mandrel 3026.
- Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.
Fig. 14 Installing flange
- Drive drive shaft flange onto drive pinion until securing nut can be mounted.
Fig. 15 Tighten nut for drive pinion and adjusting friction torque
- Screw in two hex nuts M8 x 30 -A-.
B - Socket, long A/F 36
- When the nut is tightened the final drive must be supported (e.g. with universal transmission mounting 1359/2 in conjunction with engine/transmission jack VAG 1383 A).
Note:
^ Only increase tightening torque slowly and read-off frictional torque frequently. If the specified frictional torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. It is not possible to re-use a spacer sleeve that has been excessively compressed.
Fig. 16 Measuring frictional torque
Note:
^ Do not lubricate new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.
With torque gauge, 0 to 600 Ncm, standard commercially available
B - Socket, A/F 36
Note:
Use 3/4" to 1/2" reducer as necessary.
The following frictional torques should be set:
Fig. 17 Removing nut for drive pinion
- When the nut has been locked the radial run-out on the drive shaft flange should be measured.