Rear Final Drive Pinion Shaft, Removing and Installing / Disassembling and Assembling
Rear final drive pinion shaft, removing and installing / disassembling and assembling
Special tools and equipment
^ VW 391 Driveshaft installation appliance
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 408A Press tool
^ VW 412 Press tool
Special tools and equipment
^ VW 457 Support rail
^ VW 460 Removal device
^ VW 470/1 Assembly ring
^ VW 519 Tube
^ VW 540 Engine and transmission support
^ 30-205 Thrust plate
Special tools and equipment
^ 2003/3 Installation ring
^ 3005 Press disk
^ 3028 Counter-hold
^ 3062 Press disk
^ 3138 Driver
^ 3143 Press tool
Special tools and equipment
^ VW 771 Multipurpose tool
^ 3026 Drift
^ 3253 Installation tool
^ VAG 1383A Engine and transmission jack with universal transmission support VAG 1359/2
Not illustrated:
^ Torque gauge, 0 600 Ncm, commercially available
^ Deep socket insert, 36 mm
^ 40-21 Sleeve
Note:
^ Always replace both tapered roller bearings together as a set.
^ Install new tapered roller bearings as supplied and do not oil additionally.
^ Components marked with [1] require adjustment work when they are replaced; Refer to Adjustment overview.
Clamp rear final drive in assembly bracket; Refer to Fig 1.
1. Nut
^ Removing; Refer to Fig 2
^ Installing; Refer to Fig. 16
^ Measuring friction torque; Refer to Fig. 17 - Securing - Fig. 18
2. Flange
^ For driveshaft
^ Pulling off - Fig.3
^ Installing; Refer to Fig. 15
3. Oil seal
^ Driving in; Refer to Fig. 14
4. Seal
^ Always replace
^ Insert with transmission oil; Refer to Fig. 13
5. Small tapered roller bearing inner race [1]
^ Pressing out pinion shaft
^ Installing; Refer to Fig. 12
6. Small tapered roller bearing outer race[1]
^ Pulling out - Fig.6
^ Pressing in; Refer to Fig. 11
7. Spacer sleeve[1]
^ Always replace
8. Rear axle housing[1]
9. Shim S3
10. Large tapered roller bearing outer race[1]
^ Knocking out; Refer to Fig 7
^ Pressing in; Refer to Fig. 10
11. Large tapered roller bearing inner race[1]
^ Pressing off; Refer to Fig.8
^ Pressing on; Refer to Fig.9
12. Pinion shaft[1]
^ Is mated with ring gear; always replace together as a set
Fig. 1 Clamping rear final drive to assembly bracket
Fig. 2 Removing nut for pinion shaft
A - Two Me x 30 hex bolts.
B - Deep socket insert, 36 mm AF
Note: The final drive must be supported (e.g. with universal transmission mounting VAG 1359/2 in conjunction with transmission jack VAG 1383 A) when the nut is loosened.
Fig. 3 Pulling flange off
A - Two Me x 30 hex bolts inserted into flange
Fig. 4 Pulling out oil seal for driveshaft flange
Fig. 5 Pressing pinion shaft out of tapered roller bearing inner race
Fig. 6 Pulling out small tapered roller bearing outer race
A - Counter support, e g Kukko 22/2
B - Internal puller 46 - 56 mm, e g. Kukko 21/7
Fig. 7 Driving out large tapered roller bearing outer race
- After removing check shims for damage.
Fig. 8 Pressing off large tapered roller bearing inner race
A - Separating device 22 - 115 mm, e g. Kukko 17/2
Fig. 9 Pressing on large tapered roller bearing inner race
WARNING!: Wear protective gloves!
- Heat inner ring to approximately 100°C before pressing on.
Fig. 10 Pulling in large tapered roller bearing outer race
- Install previously determined drive pinion shim "S3".
Inscription "open" (top) on thrust washer 3253/4 faces nut of puller.
Fig. 11 Pressing in small tapered roller bearing outer race
- Start insertion of outer race with drift VW 295 and thrust plate 30-205.
Fig. 12 Inserting small tapered roller bearing inner race
- Insert pinion shaft with new spacer sleeve.
WARNING!: Wear protective gloves!
- Heat inner ring to approximately 100°C
- Press pinion shaft up and press inner race fully home onto stop with press sleeve 40-21.
Fig. 13 Installing seal
- Coat seal with transmission oil and insert.
Fig. 14 Driving in new oil seal for driveshaft flange
- Apply gear oil to circumference of seal.
- Half fill space between sealing lip and dust lip with grease G 052 128 A1.
- Drive new oil seal in onto stop in rear axle housing taking care not to tilt seal.
Fig. 15 Installing flange
- Drive driveshaft flange onto pinion shaft until securing nut can be installed.
Fig. 16 Tightening nut for pinion shaft and adjusting friction torque
A - Two Me x 30 hex bolts
B - Deep socket insert, 36 mm AF
Note:
^ The final drive must be supported (e.g. with universal transmission mounting VAG 1359/2 in conjunction with transmission jack VAG 1383 A) when the nut is tightened.
^ Increase tightening torque slowly and check friction torque at regular intervals. If the prescribed friction torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. A spacer sleeve which has been compressed too much cannot be reused.
Fig. 17 Measuring friction torque
A - Torque gauge, 0 - 600 Ncm, commercially available
B - Deep socket insert, 36 mm AF
Setting friction torque
Note: Use reducer 3/4" to 1/2" if necessary.
Fig. 18 Securing nut for pinion shaft
- After securing nut, measure radial run-out at driveshaft flange.