Drive Pinion and Hollow Shaft, Disassembling and Assembling
01E, 6 Spd. M/T AWD
Drive pinion and hollow shaft, disassembling and assembling
Special tools and equipment:
^ VW 295 Drift
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Thrust tool
^ VW 411 Thrust tool
^ VW 412 Thrust tool
Special tools and equipment (continued):
^ VW 415 A Tube
^ VW 457 Mount rails
^ VW 771 Multi-purpose tool
^ 2003/3 Inserter ring
^ 3013 Fitting drift
^ 3062 Thrust disk
Special tools and equipment (continued):
^ 3118 Tube
^ 3138 Drift
^ V.A.G 1416 Hot-air blower
^ 1 - Internal puller 21 /1
^ 3 - Kukko 17/2 Separating tool
Note:
^ When installing new gears or the final drive set consult technical data.
1) Adjustments are required if these components are replaced go to Adjustment overview.
1 - Transmission housing
^ Servicing
2 - Shim S3
^ Adjustment
3 - Taper roller bearing outer race, large 1)
^ Pulling out go to Fig. 1
^ Pressing in go to Fig. 3
4 - Drive pinion 1)
^ Is mated with ring gear, replace together as a set
^ Adjusting drive pinion and ring gear
5 - Needle bearing
^ For flanged shaft/drive pinion
^ Pulling out go to Fig. 4
^ Tapping in go to Fig. 5
6 - Taper roller bearing inner race, large 1)
^ Pressing off go to Fig. 6
^ Pressing on go to Fig. 7
^ Low friction bearing; do not oil when measuring frictional torque
7 - Circlip
^ Redefine thickness go to Fig. 8
8 - Flange ring
^ Installation position
9 -Taper rollers
^ 23 pieces
^ Installation position
10 - Supporting ring
^ Installation position
11 - Corrugated spring
12 - Needle bearing
^ For drive pinion/hollow shaft
^ Oil with gear oil before installing
13 - Hollow shaft 1)
^ With gear wheels for 3rd and 4th gear
14 - Needle bearing
^ For 2nd sliding gear
^ Oil with gear oil before installing
15 - 2nd sliding gear
^ Pressing off go to Fig. 12
^ Before installing, insert spring and slide needle bearing onto hollow shaft
^ After installation, check axial play using feeler gauge (0. 15 to 0.35 mm)
16 - 2nd gear synchro-ring
^ Coated with molybdenum
^ Checking for wear, go to Fig. 2
17 -Synchro-hub for 1st and 2nd gear
^ Pressing off go to Fig. 12
^ Pressing on go to Fig. 13
^ Installation position: Flush hub toward 2nd sliding gear
18 -Circlip
^ Removing and installing go to Fig. 11
^ Redefine thickness go to Fig. 8
19 - Washer
^ For needle bearing for 1st sliding gear
^ Removing and installing go to Fig. 11
20 - Locking collar, 1st and 2nd gear
^ Installation position: Splines for reverse gear facing synchro-ring for 2nd gear
21 - 1st gear synchro-ring
^ Checking for wear, go to Fig. 2
22 - Needle bearing
^ or 1st sliding gear
^ Oil with gear oil before installing
23 - 1st sliding gear
^ Before installing, insert spring, go to Fig. 1
^ After pressing on -item 24-, check axial play using feeler gauge (0.15 to 0.35 mm)
24 -Taper roller bearing inner race, small 1)
^ Pressing off go to Fig. 9
^ Pressing on go to Fig. 10
^ Low friction bearing; do not oil when measuring frictional torque
25 - Taper roller bearing outer race, small 1)
^ Tapping out go to Fig. 15
^ Pressing in go to Fig. 16
26 - Shim S4
^ Adjustment overview
27 - Bearing plate 1)
^ Servicing
28 - 6th gear wheel
^ Pressing off
^ Pressing on
^ Installation position: Shoulder faces toward inner race of small taper roller bearing
29 - Spacer sleeve
30 - Washer
^ Re-determining thickness
31 - 5th gear wheel
^ Pulling off
^ Driving on
32 - Circlip
^ For 5th gear wheel
^ Re-determining thickness
33 - End cover
^ Servicing
Fig. 1 Pulling out large taper roller bearing outer race
Stepped side of thrust pad 3062 rests against the outer race
Fig. 2 Heating transmission housing in order to install outer race for taper roller bearing
- Heat transmission housing in area of bearing seat for approximately 15 minutes, to approximately 100°C, with a hot air blower.
WARNING! Wear protective gloves!
Fig. 3 Inserting outer race for large taper roller bearing in transmission housing and pressing home
- Insert outer race only after heating transmission housing and push into position under workshop press until heat exchange has taken place.
WARNING! Wear protective gloves!
Fig. 4 Removing needle bearing for flanged shaft/drive pinion
A - Internal extractor 12 to 14.5 mm, e.g. Kukko 21/1
Fig. 5 Inserting needle bearing for flanged shaft/drive pinion flush
Fig. 6 Pressing off large taper roller bearing inner race
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Bearing is destroyed when pressing off.
Fig. 7 Pressing on inner race for taper roller bearing
- Heat inner race to approximately 100°C and install.
WARNING! Wear protective gloves!
- Press home ensuring there is no axial play.
Fig. 8 Determining thickness of circlip
- Determine the thickest circlip that will still just fit and install.
The following circlips are available:
Fig. 9 Pressing off inner race of small taper roller bearing together with 1st sliding gear
Note: Do not press off together with synchro-hub for 1st and 2nd gear and 2nd gear sliding wheel.
Fig. 10 Pressing on inner race for small taper roller bearing
- Oil needle bearing.
- Install circlip, washer for 1st/2nd gear synchro-hub, synchro-ring for 1st gear and 1st sliding gear together with spring and needle bearing.
- Heat inner race to approximately 100°C and install.
WARNING! Wear protective gloves!
- Press home ensuring there is no axial play.
Notes:
^ Press down only on bearing inner race with collar of thrust pad 3118.
^ Position shoulder of pipe section VW 415 A facing up toward press tool VW 412
^ After pressing on, check axial play of 1st sliding gear.
Fig. 11 Removing and installing circlip of synchro-hub and washer of 1st sliding gear
- To remove circlip, remove washer -A- and then circlip -B-.
- To install circlip, install on circlip -B- and then washer -A-.
Fig. 12 Pressing off 2nd gear sliding wheel with synchro-hub for 1st and 2nd gear
- Remove locking collar for 1st and 2nd gear and synchro-ring for 1st gear.
- Remove washer and circlip for synchro-hub.
- Press off 2nd speed sliding wheel with synchro-hub for 1st and 2nd gear
Note: Do not press off together with 1st sliding gear and inner race of small taper roller bearing.
Fig. 13 Installing 2nd sliding gear, pressing on synchro-hub for 1st and 2nd gear
- Install needle bearing, sliding gear (with spring) and synchro-ring for 2nd gear.
- Oil needle bearing.
- Heat synchro-hub to approximately 100°C and install.
WARNING! Wear protective gloves!
- Press home ensuring there is no axial play.
Notes:
^ Install on pipe section VW 415 A with shoulder facing synchro-hub.
^ Position thrust pad 3118 with shoulder facing press tool VW 412.
Fig. 14 Determining size of circlip for synchro-hub for 1st and 2nd gear
- Determine the thickest circlip that will still just fit.
- Insert circlip in direction of arrow to synchro-hub.
The following circlips are available:
Fig. 15 Driving out outer race for small taper roller bearing
Fig. 16 Pressing in outer race/small taper roller bearing
- Insert shim S4 into bearing plate behind bearing seat.
- Position thrust pad 3062 with shoulder facing press tool VW 407.
- Pressing in outer race for small taper roller bearing onto stop