Drive Pinion, Removing and Installing

Special Tools And Equipment
^ VW 295 Drift
^ VW 402 Press plate
^ VW 408 A Press tool
^ VW 432 Press piece
^ VW 447 i Thrust plate
^ VW 454 Press piece





^ VW 510 Press piece
^ VW 516 Tube
^ 30-204 Installing ring
^ 30-555 Thrust piece
^ 32-109 Tube
^ 40-203/ 1 Tube, split





^ 3155 Ring nut wrench
^ 3183 A Castellated box wrench
^ 3274 Adapter
^ VAG 1582 Tapered roller bearing puller
^ VAG 1582/4 Clamping ring
^ Kukko 20-10 Puller
^ V/1 72 Removal hook

Note:
^ Before installing final drive measure friction torque at axle shaft.
^ To remove drive pinion, remove selector shaft and parking lock.





1. Drive pinion
^ Number of teeth. Refer to Application and ID.
^ Adjusting. Refer to Adjusting.
^ Removing refer to Fig. 8
2. Transmission housing
3. Screw
^ 12 Nm (9 ft. lbs.)
^ Remove screw before removing or installing bearing support ring -item 13-.
^ Insert with sealing compound AKD 456 000 01
4. Nut
^ 250 Nm (184 ft. lbs.)
^ Engage parking lock to remove or install
^ Secure with drift
5. Output gear
^ Number of teeth. Refer to Application and ID.
^ Pulling off refer to Fig. 1
^ It signs of damage exist, always replace input gear and output gear together
6. Tapered roller bearing inner race
^ Pulling off refer to Fig. 2
^ Pressing on refer to Fig. 3
^ When replacing note transmission build date
7. Tapered roller bearing outer race
^ Drive out with drift
^ Pressing in refer to Fig. 4
8. ATF oil deflector
^ Install together with bearing cap -item 10-
9. Bolt
^ 25 Nm (18 ft. lbs.)
10. Bearing cap
11. Shim
^ Determining thickness.
12. Parking lock gear
^ Rounded side faces teeth of drive pinion
13. Bearing support ring
^ 200 Nm (148 ft. lbs.)
^ Remove screw -item 3- before removing or installing bearing support ring.
^ Removing or installing refer to Fig. 5
^ Bearing support ring cannot be removed until selector shaft has been removed. Refer to Shift Interlock; Shift Interlock Solenoid; Service and Repair.
^ Insert bearing support ring carefully. Sealing lip and spring must not be damaged.
^ Support ring with seal refer to Fig. 6
14. O-ring
^ Always replace
^ Place on bearing support ring -item 13-
15. Oil seal for drive pinion
^ Remove with screwdriver
^ Installation position refer to Fig. 6
^ Driving in refer to Fig. 7
16. Tapered roller bearing outer race
^ Driving in refer to Fig. 9
17. Tapered roller bearing inner race
^ Drive off with drift
^ Pressing on refer to Fig. 10
^ When replacing note transmission build date.





Fig. 1 Output gear, removing (pulling off)
A-Kukko 20-10 and Matra V 172 pulling hooks.





Fig. 2 Tapered roller bearing inner race, removing (pulling off)
- Place press piece on output gear collar.





Fig. 3 Tapered roller bearing inner race, installing (pressing on)

Note:
^ When replacing bearing check transmission build date.





Fig. 4 Tapered roller bearing outer race, pressing in





Fig. 5 Bearing support ring, removing and installing
- Remove locking bolt.
A-Torque wrench
- Tighten bearing support ring to 200 Nm (148 ft. lbs.) and secure with locking screw. Install screw with AKD 456 000 01.





Fig. 6 Bearing support ring with seal for drive pinion
Seal installation position:
Open side (arrow) faces toward tapered roller bearing outer race





Fig. 7 Drive pinion oil seal, installing (driving in)
- Insert oil seal so sealing surface faces out to special tool 30-204.





Fig. 8 Drive pinion, removing
A-Box wrench 32 mm





Fig. 9 Tapered roller bearing outer race, installing (driving in)
- Insert drive pinion with tapered roller bearing inner race, then drive in outer race.





Fig. 10 Tapered roller bearing inner race, installing (pressing on)

Note:
^ When replacing bearing check transmission build date.