Drive Pinion, Removing, Installing, Disassembling / Assembling

Drive pinion, removing, installing, disassembling and assembling
Special tools, testers and auxiliary items
^ Press plate VW 401
^ Press plate VW 402
^ Press tool VW 407
^ Press tool VW 408 A
^ Press tool VW 412
^ Support rails VW 457
^ Mandrel VW 460/2
^ Tube VW519
^ Engine and transmission support VW 540
^ Thrust plate 30-205
^ Installing ring 2003/3
^ Pinion assembly appliance 2052/2
^ Thrust plate 3005
^ Thrust pad 3062
^ Drift 3138
^ Fitting appliance 3253 with 3253/3 and 3253/4
^ Retainer 3304
^ Engine/transmission jack V.A.G 1383 A
^ Universal support V.A.G 1359/2
^ Separating tool Kukko 17/2
^ Two-arm puller Kukko 21/7
^ Counter-support Kukko 22/2
^ Torque gauge 0-600 Ncm
^ Socket attachment (long), 32 mm A/F

Note:
^ General repair instructions, Refer to Manual Transaxle, Service and Repair.
^ Removing drive flange housing from rear final drive with final drive installed, Refer to Removing Drive Flange Housing From Rear Final Drive
^ Removing drive flange housing from rear final drive with final drive removed, Removing Drive Flange Housing From Rear Final Drive
^ Replace both tapered roller bearings together. Use same make if possible.
^ Do not additionally oil new tapered roller bearings for friction torque measurement. The bearings have already been treated with a special oil by the manufacturer.
^ Removing differential, Refer to Differential, Removing and Installing
^ Adjustments are required when replacing components marked with a 1), Refer to Differential Assembly, Adjustments, Adjustment overview





1. Nut
^ Always replace
^ Removing, Refer to Fig.1 and Fig. 2
^ Installing, Refer to Fig. 11
^ Measuring friction torque, Refer to Fig. 12
^ Securing, Refer to Fig. 13
2. Inner race for small tapered roller bearing 1)
^ Pressing out drive pinion, Refer to Fig. 3
^ Installing, Refer to Fig. 10
3. Outer race for small tapered roller bearing 1)
^ Pulling out, Refer to Fig. 4
^ Pressing in, Refer to Fig. 3
4. Spacer sleeve 1)
^ Always replace
5. Final drive housing 1)
6. Shim "S3"
^ Note thickness
^ Adjustment overview, Refer to Differential Assembly, adjustments
7. Outer race for large tapered roller bearing 1)
^ Driving out, Refer to Fig. 5
^ Pulling in, Refer to Fig. 8
8. Inner race for large tapered roller bearing 1)
^ Pulling off, Refer to Fig. 6
^ Pressing on, Refer to Fig. 7
9. Drive pinion 1)
^ Is mated with ring gear, always replace together as a set





Fig. 1 Tools for loosening and tightening drive pinion nut
A- Socket (32 mm)





Fig. 2 Removing nut for drive pinion
- Secure retainer 3304 with two M8 x 30 hex bolts.
- Support final drive when loosening nut (e.g. using universal support V.A.G 1359/2 in combination with transmission jack V.A.G 1383 A).





Fig. 3 Pressing drive pinion out of inner race for small tapered roller bearing





Fig. 4 Pulling out outer race for small tapered roller bearing
A - Counter support e.g. Kukko 22/2
B - Internal puller 46-58 mm, e.g. Kukko 21/7





Fig. 5 Driving out outer race for large tapered roller bearing
After removing check shims for damage.





Fig. 6 Pressing inner race for large tapered roller bearing off drive pinion
A- Separating device 22-115 mm, e.g. Kukko 17/2





Fig. 7 Pressing inner race for large tapered roller bearing onto drive pinion

CAUTION: Wear protective gloves.

- Heat bearing to approximately 100°C, fit in position and press home.





Fig. 8 Pulling in outer race for large tapered roller bearing
- Insert predetermined shim "S3" for drive pinion, Refer to Differential Assembly, adjustments

Note: Inscription "Oben" faces the nut of the puller with thrust washer 3253/4.





Fig. 9 Pressing in outer race for small tapered roller bearing
- Lubricate outer race with oil and fit using press tool VW 408 A and thrust plate 30-205.





Fig. 10 Pressing on small tapered roller bearing inner race

CAUTION: Wear protective gloves

- Insert drive pinion with new spacer sleeve.
- Heat inner race for small tapered roller bearing to approximately 100°C and fit onto drive pinion.
- Press up drive pinion and insert bearing with thrust plate 40-21 onto stop.





Fig. 11 Tightening nut for drive pinion and measuring friction torque
- Secure retainer 3304 with two Me x 30 hexagon bolts.
- Support final drive when tightening nut (e.g. using universal support V.A.G 1359/2 in conjunction with transmission jack V.A.G 1383 A).
- Fit a new drive pinion nut.
- Tighten drive pinion nut just far enough so that no play can be felt at drive pinion.
- Gradually increase tightening torque, checking friction torque at regular intervals, until specified friction torque is obtained , Refer to Fig. 12.

Note: If the specified 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. 12 Measuring friction torque
A - Torque gauge, commercially available, 0-600 Ncm
B - Extension with 32 mm socket





- The following friction torques should be set:
1) run at least 50 km (30 miles)





Fig. 13 Securing drive pinion nut
- Peen drive pinion nut with punch.