Needle Bearings For Spur Gear -2-, Replacing

5 SPD. A/T 01L AWD

Needle bearings for spur gear -2-, replacing





Special tools and equipment
^ VW402 Thrust plate
^ VW408A Punch
^ Press sleeve for 2080A sleeve
^ Item 1 Kukko 21/2 and Kukko 21/5 extractors
^ Item 3 Kukko 22/1 support
^ VAG 1416 Hot air blower

Removing

Note:
^ Remove needle bearing to replace.
^ The needle bearing is damaged during removal

^ Remove transfer case.





^ Unbolt output flange by securing output flange against turning using two bolts and a metal bar.
^ Carefully press out tension nut,= item 14, toward inside.
^ Remove bolts,= item 22. (5 pieces, T25).
^ Remove guide plate and securing disc





A: Kukko 22/1 support
B: Kukko 22/2 extractor
^ Attach support -A- and extractor -13- to spur gear shaft -2- as illustrated.
^ Support support -A- using VW402 thrust plate and pre-tension at nut -1- of retainer.
^ Pull out spur gear -2- and carefully remove upward.

Note: Make sure that the sender for transmission output RPM -G195- that is threaded in to the transfer housing is not damaged when removing spur gear -2-.

CAUTION: Spur gears which have fallen onto the ground may not be reinstalled. In this case the transfer case must be replaced.

^ Remove circlip; Refer to item 16.





A: Kukko 22/1 support
B: Kukko 21/5 extractor

Note: The upper part of the illustration shows how the pulling hooks of the extractor -B- must be installed in the needle bearing.

^ Slide centering sleeve -2- of extractor -B- approximately 4 mm into direction of arrow in order to be able to open pulling hooks of extractor enough.
^ Spread extractor -B- into upper lip of needle bearing -1- and secure extractor at nut
^ Install retainer -A- on extractor -13- as illustrated.
^ Support support -A- using VW402 thrust plate and pre-tension at nut -3- of retainer.
^ Using hot air blower, quickly heat up outside of transfer housing in vicinity of needle bearing seat to approximately 80 to 100°C.

CAUTION: Wear protective gloves.

^ Quickly pull out needle bearing.

Installing
Installation is the reverse of removal. Also carry out the following procedures:
^ Check needle bearing seat in transfer housing for damage, rework if necessary.
^ Using hot air blower, uniformly heat up outside of transfer housing in vicinity of needle bearing seat to approximately 80 to 100°C.





^ Set new needle bearing in place and set 2080A sleeve onto new needle bearing -1-.

Note: The sleeve must be centered when set onto sleeve.

^ Drive needle bearing flush into transfer housing to stop using special tool VW408.
^ Insert circlip,= item 16, for securing needle bearing.
^ Carefully insert spur gear -2-.
^ Insert guide plate and mounting disc and secure with bolts.
^ Install tension nut, item 14.

Note: The following test steps must be performed before installing the transfer case:

^ Check O-ring for output flange/drive shaft for damage or leaks and replace if necessary.
^ Check double oil seal for intermediate flange for front final drive for damage or leaks and replace if necessary.





Tightening torques
Mounting bolt (T25) for mounting disc and guide plate 8 Nm
Transfer housing to rear transmission flange 23 Nm
Socket-head bolt for rear drive flange 25 Nm
Heat shield for drive shaft to transmission 23 Nm