Pinion Shaft, Removing and Installing/Disassembling and Assembling
Pinion shaft, removing and installing/disassembling and assembling, 01A, 5 SPD. M/T (AWD)
Special tools, testers and auxiliary items required:
^ Puller VW 391
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 407
^ Punch VW 408 A
^ Thrust Disc VW412
Special tools, testers and auxiliary items required:
^ Support channels VW 457
^ Pressing off device VW 460
^ Installation ring VW 470/1
^ Sleeve VW 519
^ Holding fixture VW 540
^ Thrust pad 30-205
Special tools, testers and auxiliary items required:
^ Seal installer 2003/3
^ Thrust pad 3005
^ Retainer 3028
^ Thrust pad 3062
^ Drift 3138
^ Seal driver-frt wheel bearing 3143
Special tools, testers and auxiliary items required:
^ Slide hammer-complete set VW 771
^ Mandrel 3026
^ Wheel Bearing Assembly Set 3253
^ Engine/transmission jack V.A.G 1383 A
^ 1 - Internal extractor Kukko 21/7
^ 3 - Separating tool Kukko 17/2
^ 4 - Support Kukko 22/2
^ Torque gauge 0 to 600 Ncm
^ 36 mm wrench socket insert
Note:
^ Clamp final drive in assembly fixture.
^ Replace both tapered roller bearings together.
^ Adjustments are required when replacing components marked with 1).
1. Nut
^ Removing
^ Bolting on
^ Measuring friction torque
^ Securing
2. Driveshaft flange
^ Pull off
^ Installing
3. Oil seal
^ Pulling out
^ Driving in
4. O-ring
^ Replace
^ Lubricate with transmission fluid before installing
5. Small tapered roller bearing inner race
^ Pressing off pinion shaft
^ Pressing on
6. Small tapered roller bearing outer race
^ Pulling out
^ Pressing in
7. Spacer sleeve
^ Replace
8. Final drive housing
9. Shim "S3"
^ Note thickness
10. Large tapered roller bearing outer race
^ Driving out
^ Pulling in
11. Large tapered roller bearing inner race
^ Pressing off
^ Pressing on
12. Pinion shaft
^ Matched to ring gear, always replace together as a set
Removing pinion shaft nut
^ Screw in two hex bolts M8x30 - A
B - 36 mm wrench socket insert
^ When loosening nut, final drive must be supported (e.g. using universal transmission support VAG 1359/2 in conjunction with Engine/transmission jack VAG 1383 A).
Pull off driveshaft flange from pinion shaft
^ Thread two hex head bolts M8 x 30 - A - into flange.
Pull out seal for driveshaft flange
Pressing out pinion shaft from small tapered roller bearing inner race
Pulling off small outer race/tapered roller bearing
A - Support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Driving out large tapered roller bearing outer race
^ After removing check shims for damage.
Pressing off large tapered roller bearing inner race from pinion shaft
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing large tapered roller bearing inner race onto pinion shaft
^ Heat inner race gear to approximately 100°C, install and press on.
CAUTION: Wear protective gloves!
Pulling in large tapered roller bearing outer race
^ Insert previously determined adjustment shim "S3" for pinion shaft.
Note:
^ At pressure disc 325314, marking "Above" points toward nut on installation device.
Pressing in small tapered roller bearing outer race
^ Outer race is to be oiled and must be installed using punch VW 408 A and thrust piece 30 - 205.
Pressing on tapered roller bearing inner race
^ Insert pinion shaft with a new spacer sleeve.
CAUTION: Wear protective gloves!
^ Heat up small tapered roller bearing inner race to approximately 100°C and insert on pinion shaft.
^ Press pinion shaft upward and insert bearing up to stop using sleeve 40 - 21.
Inserting O-ring
^ Inserting O-ring with gear oil
Driving in oil seal for driveshaft flange
^ Lightly oil outer circumference of seal.
^ Fill space between sealing lip and dust lip with grease G 052 128 Al.
^ Drive in oil seal up to stop using driver 3026.
Installing flange
^ Drive driveshaft flange far enough onto pinion shaft so that securing nut can be installed.
Tightening pinion shaft nut and adjusting friction torque
^ Screw in two hex bolts M8x30 - A
B - 36 mm wrench socket insert
^ When tightening nut, final drive must be supported (e.g. using universal transmission support V.A.G 1359/2 in conjunction with engine/transmission jack V.A.G 1383 A).
Note:
^ Increase tightening torque slowly and measure friction torque at regular intervals. If the specified friction torque is exceeded, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been compressed too far one time must be replaced.
Measuring friction torque
With standard torque gauge, 0 to 600 Ncm
B - 36 mm socket insert
Note:
^ If necessary use 314 to 112 reducing piece.
^ Adjust to following friction torque
Securing pinion shaft nut - Secure pinion shaft nut using punch.
Note:
^ Radial run-out on driveshaft flange, measuring and marking.