Pinion Gear Removing/Installing

Component Notes And Information

NOTE:
^ During service procedures, refer to the illustration above and the information below.
^ Refer to general repair instructions. Service and Repair
^ Make sure both tapered roller bearings on the pinion are replaced together. If possible, use bearings from same manufacturer
^ Do not additionally treat new tapered roller bearing to measure turning torque. For this purpose, the bearings are already pre-treated with a special oil.
^ Differential gear, removing refer to Removing/Installing. Removing/Installing

1 Pinion nut
- Removal Fig. 2 below
- Tightening Fig. 16 below
- In this process, measure turning torque refer to Fig. 17 below
- Securing refer to Fig. 18 below
2 Drive shaft flange
- Removal refer to Fig. 3 below
- Installation refer to Fig. 15 below
- Radial runout, measuring. Testing and Inspection
3 Sealing ring for drive shaft flange
- Removal refer to Fig. 4 below
- Installation, refer to Fig. 14 below
4 O-ring
- Always replace
- Installation refer to Fig. 13 below
5 Outer race of small tapered roller bearing
- Pinion, pressing out refer to Fig. 5 below
- Installation refer to Fig. 12 below
6 Outer race of small tapered roller bearing
- Pulling out refer to Fig. 6 below
- Pressing in refer to Fig. 11 below
7 Spacer sleeve
- Always replace
8 Final drive housing
9 Shim S3
- Note thickness
- Adjustment summary. Adjustment Summary
10 Outer race of large tapered roller bearing
- Driving out refer to Fig. 7 below
- Pulling in refer to Fig. 10 below
11 Inner race of large tapered roller bearing
- Pulling off refer to Fig. 8 below
- Pressing on refer to Fig. 9 below
12 Pinion
- Matched with ring gear
- Must only be replaced together with ring gear

Procedures





Fig. 1 Clamping Final Drive In Vise





Fig. 2 Loosening Pinion Nut
- Install retainer 3028 using M8 x 30 mounting bolts.

CAUTION: The final drive must be supported (e.g. with VAG 1383 A), when the pinion nut is loosened otherwise, the threaded holes in the housing can be damaged





Fig. 3 Pulling Drive Shaft Flange Off Of Pinion
A - Hex bolt M8 x 30





Fig. 4 Pulling Out Sealing Ring





Fig. 5 Pressing Pinion Out Of Inner Race Of Small Tapered Roller Bearing

NOTE: The illustration shows the incorrect special tool. Installation ring tool No 10-9 must be used instead of VW 204b.





Fig. 6 Pulling Out Outer Race Of Small Tapered Roller Bearing
A - Support, Kukko 22/2
B - Extractor, standard commercial, e.g. Kukko 21/7
C - Installation ring tool No. 10-9





Fig. 7 Driving Out Outer Race Of Large Tapered Roller Bearing

NOTE:
^ The illustration shows the incorrect special tool. Installation ring tool No. 10-9 must be used instead of VW 204b.
^ The shim(s) are damaged during removal.





Fig. 8 Pressing Inner Race Of Large Tapered Roller Bearing Off Of Pinion
A - Separating tool, e.g. Kukko 17/2, 22-115 mm





Fig. 9 Pressing Inner Race Of Large Tapered Roller Bearing On To Pinion
- Warm bearing to approx. 100°C (212°F), install and press down.





Fig. 10 Pulling In Outer Race Of Large Taper Bearing
- First, install shims for pinion.

NOTE: On the pressure piece 3253/4, the inscription "top" faces the nut on the pulling device.





Fig. 11 Pressing In Outer Race Of Small Tapered Roller Bearing
- Before pressing in, install bearing outer race uniformly using VW 295 and 30-205.

NOTE: The illustration shows the incorrect special tool. Installation ring tool No. 10-9 must be used instead of VW 204b.





Fig. 12 Installing Inner Race Of Small Tapered Roller Bearing
- Install pinion together with new spacer sleeve.
- Warm inner race of small tapered roller bearing to approx. 100°C (212°F) and place on pinion.
- Press pinion up and install bearing to stop using tool No. 40-21.





Fig. 13 Installing O-ring
- Lubricate O-ring with gear oil.





Fig. 14 Driving Sealing Ring For Drive Shaft Flange In To Stop Using 3026
- Lubricate outer circumference of sealing ring with gear oil.
- Lubricate space between sealing lip and dust lip with gear oil.





Fig. 15 Installing Drive Shaft Flange On Pinion
- Install flange carefully using driving sleeve 3143 until pinion nut can be installed.





Fig. 16 Tightening Pinion Nut And Adjusting Tightening Torque
A - Socket, 36 mm

CAUTION: The final drive must be supported (e.g. with VAG 1383 A), when the pinion nut is tightened Otherwise, the threaded holes in the housing can be damaged

NOTE: Increase the tightening torque slowly, while reading the turning torque several times. If the specified turning torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. A spacer sleeve that has been compressed too much one time cannot be used again.





Fig. 17 Measuring Turning Torque
- A - Torque gauge, standard commercial; 0-600 Ncm (0-53 inch lb)
- B - Socket, 36 mm
- Turning torque specifications
New bearings: 200-250 Nm (18-22 inch lb)
Used bearings: 30-60 Ncm (3-5 inch lb)





Fig. 18 Securing Pinion Nut

NOTE: Measure and mark the radial runout on the drive shaft flange. Testing and Inspection