Pinion Gear: Service and Repair
Drive pinion, removing and installing and disassembling and assembling
Special tools and workshop equipment required
- VW 391 Drive axle fitting appliance
- VW 401 Thrust plate
- VW 402 Thrust plate
- VW 407 Press tool
- VW 408 A Press tool
- VW 412 Press tool
Special tools and workshop equipment required
- VW 457 Mounting rail
- VW 460 Removal device
- VW 470/1 Assembly ring
- VW 519 Tube
- VW 540 Engine and gearbox support
- 30-205 Thrust plate
Special tools and workshop equipment required
- 2003/3 Inserter ring
- 3005 Thrust plate
- 3028 Holding tool
- 3062 Thrust plate
- 3138 Driver
- 3143 Drift sleeve
Special tools and workshop equipment required
- VW 771 Multipurpose tool
- 3026 Fitting drift
- 3253 Assembly equipment
- V.A.G 1383 A Engine/gearbox support
Notes:
^ Replace both taper roller bearings together.
^ Install new taper roller bearings in delivery condition and do not oil additionally.
^ When replacing the parts marked with 1) adjustment work is required; Refer to Adjustment overview.
1. Nut
^ Unscrewing; Refer to Fig. 1
^ Screwing in; Refer to Fig. 15
^ Measuring friction torque; Refer to Fig. 16
^ Securing; Refer to Fig. 17
2. Flange for drive shaft
^ Pulling off; Refer to Fig 1"
^ Installing; Refer to Fig. 14
3. Sealing ring Pulling out; Refer to Fig. 3 Tapping in; Refer to Fig. 13
4. O-ring Replace Insert with gear oil; Refer to Fig. 12
5. Inner race for small taper roller bearing 1) Pressing out drive pinion; Refer to Fig Pressing on; Refer to Fig. 11
6. Outer race for small taper roller bearing 1) Pulling out; Refer to Fig. 5 Pressing in; Refer to Fig. 10
7. Spacer sleeve 1)
^ Replace
8. Final drive housing 1)
9. Shim "ST' Note thickness Adjustment overview
10. Outer race for large taper roller bearing 1) Tapping out - Fig 1 Inserting - Fig. 9
11. Inner race for large taper roller bearing 1)
12. Drive pinion)
^ Is mated with ring gear, replace together as a set
Fig. 1 Removing nut for drive pinion
- Secure final drive on a repair stand.
- Screw in two hexagon nuts M8 x 30 -A-.
- B - Socket, long A/F 36
- When the nut is loosened the final drive must be supported (e.g. with universal gearbox mounting 1359/2 in conjunction with engine/gearbox lifter VAG 1383 A).
Fig. 2 Pulling flange for drive shaft off drive pinion
- Screw two hexagon nuts M8 x 30 -A- into the flange.
Fig. 3 Pulling out seal for flange for drive shaft
Fig. 4 Pressing drive pinion out of inner race for small taper roller bearing
Fig. 5 Pulling out small taper roller bearing outer race
B - Support, e.g. Kukko 22/2
B - Internal puller 46 to 2.28 in, e.g. Kukko 21f7
Fig. 6 Driving out outer race for large taper roller bearing
- After removing check shims for damage.
Fig. 7 Pressing inner race for large taper roller bearing off drive pinion
A - Separating device 22 to 4.53 in, e.g. Kukko 17/2
Fig. 8 Pressing inner race for large taper roller bearing onto drive pinion
- Heat the inner race to approximately 100°C, position and push to final position.
WARNING!: Wear protective gloves!
Fig. 9 Pulling in outer race for large taper roller bearing
- Lightly lubricate the bearing seat in the housing.
- Insert predetermined shim 'S3" for drive pinion .
- The inscription "top" on the pressure plate 3253/4 faces the nut of the insertion device
Fig. 10 Pressing in small taper roller bearing outer race
- Lightly lubricate the bearing seat in the housing.
- The outer race must be attached with drift VW 295 and thrust plate 30205.
Fig. 11 Pressing on small taper roller bearing inner race
- Insert the new drive pinion with a new spacer sleeve.
WARNING!: Wear protective gloves!
- Heat inner race for small taper roller bearing to approximately 100°C and install onto drive pinion.
- Press up drive pinion and insert bearing with thrust plate 40-21 onto stop.
Fig. 12 Inserting O-ring
- Insert O-ring with gear oil.
Fig. 13 Tapping in seal for flange for drive shaft
- Lightly oil outer circumference of seal.
- Drive in seal onto stop with drift 3026.
- Pack space between sealing and dust lips half-full with sealing grease G 052 128 Al.
Fig. 14 Installing flange
- Drive the drive shaft flange onto the drive pinion until the securing nut can be mounted.
Fig. 15 Tighten nut for drive pinion and adjusting friction torque
- Screw in two hexagon nuts M8 x 30 -A-.
- B - Socket, long A/F 36
- When the nut is tightened the final drive must be supported (e.g. with universal gearbox mounting 1359/2 in conjunction with engine/gearbox lifter VAG 1383 A).
Note: Only increase tightening torque slowly and read off frictional torque frequently. If the specified frictional torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. It is not possible to re-use a spacer sleeve that has been excessively compressed.
Fig. 16 Measuring frictional torque
With torque gauge, 0 to 600 Nm, standard commercially available
B - Socket, A/F 36
Note: Use 314" to 112" reducer as necessary.
The following frictional torques should be set:
Fig. 17 Removing nut for drive pinion
- When the nut has been locked the radial run-out on the drive shaft flange should be measured.