Drive Pinion, Remove, Install, Disassemble and Assemble

5 Speed A/T 01V

Drive pinion, removing, installing, disassembling and assembling











Special tools and equipment
^ VW401 thrust plate
^ VW402 thrust plate
^ VW407 punch
^ VW408A punch
^ VW412 punch
^ VW457 support channels
^ VW460/2 drift
^ VW 519 sleeve to VW540 holding fixture
^ 30-205 thrust pad
^ 2003/3 sea installer
^ 2052/2 assembly tool for drive pinion
^ 3005 thrust pad
^ 3062 thrust pad
^ 3138 drift
^ 3253 wheel bearing assembly set with 3253/3 and 3253/4
^ 3304 retainer
^ Engine/transmission jack VAG 1383A engine/gearbox jack





^ Item 1: Kukko21/7 extractor
^ Item 2: Kukko 22/2 support
^ Item 3: Kukko 17/2 separator
^ Torque gauge 0-600 Ncm
^ 32 wrench insert hex socket

Notes
^ General repair notes, Refer to Automatic Transmission/Transaxle, Service and Repair
^ Disconnect torque tube from rear final drive with the final drive installed.
^ Disconnect torque tube from rear final drive with the final drive removed.
^ Replace both tapered roller bearings together. If possible, use same manufacturer!
^ Do not grease new tapered roller bearings additionally for friction torque measurement. The bearings are already greased with a special oil from the factory.
^ Removing differential.
^ Adjustments are required when replacing components marked with 1), Refer to Adjustment overview, Refer to Differential, Assembly Adjustments





1. Nut
^ Always replace
^ Unbolt, Refer to Fig. 1 and Fig. 2
^ Unbolt, Refer to Fig. 11
^ Measuring friction torque, Refer to Fig. 12
^ Secure, Refer to Fig. 13
2. Small tapered roller bearing inner race 1)
^ Press out drive pinion, Refer to Fig. 3
^ Pressing on, Refer to Fig. 10
3. Small tapered roller bearing outer race 1)
^ Pulling out, Refer to Fig. 4
^ Pressing in, Refer to Fig. 9
4. Spacer sleeve 1)
^ Always replace
5. Final drive housing 1)
6. Shim "S3"
^ Note thickness
^ Adjustment overview, Refer to Differential, Assembly Adjustments
7. Large tapered roller bearing outer race 1)
^ Driving out, Refer to Fig. 5
^ Pulling in, Refer to Fig. 8
8. Large tapered roller bearing inner race 1)
^ Pressing off, Refer to Fig. 6
^ Pressing on, Refer to Fig. 7
9. Drive pinion 1)
^ Matched to ring gear, always replace together as a set





Fig. 1 Tools for removing and installing drive pinion nut
A- 32 mm wrench socket





Fig. 2 Removing drive pinion nut
- Install 3304 retainer using two hex bolts M8 x 30.
- When nut is removed, final drive must be supported (e.g. using VAG1359/2 universal mount together with VAG1 383A transmission hoist).





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





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





Fig. 5 Driving out large tapered roller bearing outer race
- Check adjustment shims for damage after removing.





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





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

WARNING: Wear protective gloves!

- Heat inner race to approximately 100°C ,position and press on.





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

Note: On 3253/4 pressure disc, marking "Oben" points toward nut on installation device





Fig. 9 Pressing in small tapered roller bearing outer race
- The outer race must be oiled and installed using VW408A punch and 30-205 thrust pad.





Fig. 10 Pressing on small tapered roller bearing inner race

WARNING: Wear protective gloves!

- Insert drive pinion with a new spacer sleeve.
- Heat up small tapered roller bearing inner race to approximately 100°C and insert on drive pinion.
- Press drive pinion upward and insert bearing up to stop using 40-21 sleeve.





Fig. 11 Tightening drive pinion nut and adjusting friction torque
- Install 3304 retainer using two hex bolts M8 x 30.
- When tightening nut, support final drive (e.g. using VAG1359/2 universal mount with VAG 1383A transmission hoist).
- Always replace drive pinion nut.
- Tighten nut for drive pinion until no more drive pinion backlash is present.
- Tighten further until specified friction torque is attained; while tightening measure friction torque multiple times, Refer to Fig. 12.

Note: If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been pressed together too far one time must be replaced.





Fig. 12 Measuring friction torque
A- Standard torque gauge, 0 to 600 Ncm
B - Extension with 32 mm wrench socket





- Adjust to following friction torque
1) have been run in at least 50 km





Fig. 13 Removing drive pinion nut
- Peen drive pinion nut using mandrel.