Drive Pinion and Hollow Shaft, Disassembling and Assembling

Drive pinion and hollow shaft, disassembling and assembling
Special tools, testers and auxiliary items required:
^ Multi-purpose tool 771/1 with attachment 771/15
^ Installing sleeve 2003/3
^ Punch 3013
^ Thrust pad 3062
^ Thrust piece 3118
^ Drift 3138
^ Drift VW295
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Press tool VW 407
^ Press tool VW 411
^ Press tool VW 412
^ Tube VW 415a
^ Support rails VW 457
^ Separating device 22-115 mm (e.g. Kukko 17/2)
^ Internal puller 12-14.5 mm (e.g. Kukko 22/1)
^ Hot air blower V.A.G 1416

Note:
^ When installing new gears or final drive set, Refer to Manual Transaxle, Application and ID
^ Adjustments are required when replacing components marked 1), Refer to Differential, Assembly, Adjustments, Adjustment overview





1. Gearbox housing
^ Servicing, Refer to Transmission Disassembling and Assembling, Transmission housing, Servicing
2. Shim "S3"
^ Adjustment overview, Refer to Differential, Assembly, Adjustments
3. Outer race for large tapered roller bearing 1)
^ Pulling out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2 and Fig. 3
4. Drive pinion 1)
^ Paired with ring gear (final drive set)
5. Needle bearing for flange shaft/drive pinion
^ Pulling out, Refer to Fig. 4
^ Driving In, Refer to Fig. 5
6. Inner race for large tapered roller bearing 1)
^ Pressing off, Refer to Fig. 6
^ Pressing on, Refer to Fig. 7
^ Low friction bearing; do not oil when measuring friction torque
7. Circlip
^ Redetermining, Refer to Fig. 8
8. Flange ring
^ Installation position, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
9. Tapered rollers
^ Qty.23
^ Installation position, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
10. Support ring
^ Installation position, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
11. Corrugated spring
12. Needle - bearing for drive pinion/hollow shaft
^ Oil before installing
13. Hollow shaft with 3rd and 4th speed gears 1)
14. Needle bearing for 2nd speed sliding gear
^ Split
^ Oil with gear oil before installing
15. 2nd speed sliding gear
^ Pressing off, Refer to Fig. 12
^ Before installing, fit spring and slide needle bearing onto hollow shaft
^ After installing, check axial clearance with a feeler gauge (0.15-0.35 mm)
16. Synchroring for 2nd gear
^ Coated with Molybdenum
^ Checking for wear, Refer to Transmission Disassembling and Assembling, Input Shaft, Disassembling and Assembling, See Fig. 2
17. Synchrohub for 1st and 2nd gear
^ Pressing off, Refer to Fig. 12
^ Pressing on, Refer to Fig. 13
^ Installation position: flush hub towards 2nd speed sliding gear
18. Circlip
^ Removing and installing, Refer to Fig. 11
^ Redetermining, Refer to Fig.8
19. Washer
^ Removing and installing, Refer to Fig. 11
20. Locking collar for 1st and 2nd gear
^ Installation position: splines for reverse gear towards synchroring for 2nd gear
21. Synchroring for 1st gear
^ Checking for wear, Refer to Transmission Disassembling and Assembling, Input Shaft, Disassembling and Assembling, See Fig. 2
22. Needle bearing for 1st speed sliding gear
^ Oil with gear oil before installing
23. 1st speed sliding gear
^ Before installing, insert spring, Refer to Transmission Disassembling and Assembling, Input Shaft, Disassembling and Assembling, See Fig. 1
^ After pressing on -item 24 -, check axial clearance
24. Inner race for small tapered roller bearing 1)
^ Pressing off, Refer to Fig. 9
^ Pressing on, Refer to Fig. 10
^ Low friction bearing; do not oil when measuring friction torque
25. Outer race for small tapered roller bearing 1)
^ Driving out, Refer to Fig. 15
^ Pressing in, Refer to Fig. 16
26. Shim "S4"
^ Adjustment overview, Refer to Differential, Assembly, Adjustment
27. Bearing plate 1)
^ Servicing, Refer to Transmission Disassembling and Assembling, Bearing Plate, Servicing
28. 6th gear wheel
^ Pressing off, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
^ Pressing on, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
^ Installation position: shoulder towards inner race for small tapered roller bearing
29. Spacer sleeve
30. Shim
^ Redetermining, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
31. 5th gear wheel
^ Pulling off, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
^ Driving on, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
32. Circlip for 5th gear wheel
^ Redetermining, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
33. End cover
^ Servicing, Refer to Transmission Disassembling and Assembling, End Cover Servicing





Fig. 1 Pulling out outer race for large tapered roller bearing
Stepped side of thrust pad 3062 rests against the outer race





Fig. 2 Heating gearbox housing to insert the outer race for large tapered roller bearing
- Heat gearbox housing in area of bearing seat for approximately 15 minutes, to approximately 100°C, with a hot air blower.





Fig. 3 Inserting outer race for large tapered roller bearing in gearbox housing and pressing home
- Insert outer race only after heating gearbox housing and press home for 1-2 minutes under a repair press until a heat exchange has taken place.





Fig. 4 Pulling out needle bearing for flange shaft/drive pinion
A- Internal puller 12-14.5 mm, e.g. Kukko 21/1





Fig. 5 Driving needle bearing for flange shafts drive pinion in flush





Fig. 6 Pressing off inner race for large tapered roller bearing
A- Separating device 22-115 mm, e.g. Kukko 17/2
^ Bearing is destroyed when pressing off





Fig. 7 Pressing on inner race for large tapered roller bearing
- Heat inner race to approximately 100°C and fit.
- Press home ensuring there is no axial play.





Fig. 8 Determining circlip for large tapered roller bearing for drive pinion
- Determine thickest circlip that can still just be fitted.
- Determine circlip from table.
Refer to Parts Supplier





The following circlips are available:
- Fit circlip.





Fig. 9 Pressing off inner race of small tapered roller bearing for drive pinion together with 1st speed sliding gear

Note: Do not press off together with 1st and 2nd gear synchro-hub and 2nd speed sliding gear.





Fig. 10 Pressing on inner race for small tapered roller bearing for drive pinion together with 1st speed sliding gear
- Install circlip, shim for 1st speed sliding gear, synchro-ring for 1st speed, and 1st speed sliding gear with spring and needle bearing.
- Heat inner race to approximately 100°C and fit.
- Press home ensuring there is no axial play.

Note:
^ With shoulder of thrust piece 3118 facing downwards, press only onto bearing inner race.
^ Position stepped shoulder of tube VW415A facing up towards press tool VW 412.
^ After pressing on, check axial clearance of 1st speed sliding gear.





Fig. 11 Removing and installing circlip for synchro-hub and shim for 1st speed sliding gear
- Removing: take off shim -A- then circlip -B-.
- Installing: fit circlip -B- then shim -A-.





Fig. 12 Pressing off 2nd speed sliding gear with synchrohub for 1st and 2nd gear
- Take off locking collar for 1st and 2nd gear and synchro-ring for 1st gear.
- Remove shim and circlip for synchrohub.
- Press off 2nd speed sliding gear together with synchro-hub for 1st and 2nd gear.

Note: Do not press off together with 1st speed sliding gear and inner race for small tapered roller bearing.





Fig. 13 Fitting 2nd speed sliding gear, pressing on synchrohub for 1st and 2nd gear
- Install needle bearing (split), sliding gear with spring and synchro-ring for 2nd gear.
- Oil needle bearing.
- Heat synchro-hub to approximately 100°C and fit.
- Press home ensuring there is no axial play.

Note:
^ Position tube VW 415 a with shoulder towards synchro-hub.
^ Position thrust pad 3118 with stepped shoulder towards press tool VW412.





Fig. 14 Determining thickness of circlip for synchro-hub for 1st and 2nd gear
- Determine thickest circlip that can still just be fitted.
- Determine circlip from table.
Refer to Parts Supplier





The following circlips are available:
- Fit circlip in direction of arrow onto synchro-hub.





Fig. 15 Driving out outer race for small tapered roller bearing





Fig. 16 Pressing in outer race for small tapered roller bearing
- Insert shim "S4" into bearing flange behind bearing seat.
- Position stepped shoulder of thrust pad 3062 towards press tool VW 407.
- Press outer race for small tapered roller bearing onto stop.