Drive Pinion, Removing and Installing, Disassembling and Assembling
5 SPD. A/T 01L AWD
Drive pinion, removing and installing, disassembling and assembling
Special tools and equipment
^ VAG 1383A Engine/transmission hoist
^ VAG 1359/2 Universal mount
^ VW391 Puller
^ VW401 Thrust plate
^ VW402 Thrust plate
^ VW408A Punch
^ VW412 Punch
^ VW457 Support channels
^ VW460/2 Drift
^ VW470/1 Thrust shell for drive pinion bearing
^ VW540 Holding fixture
^ VVV771 Slide hammer-complete set with 771/37
^ 30-205 Thrust pad
^ 2003/3 Seal installer
^ 3005 Thrust pad
^ 3026 Mandrel
^ 3028 Retainer
^ 3062 Thrust pad
^ 3138 Drift
^ 3143 Seal driver
^ 3253 Wheel bearing assembly set with 3253t3 and 3253/4
^ Kukko 17/2 Separator
^ Kukko 21/7 Extractor
^ Kukko 22/2 Support
^ Torque gauge (0-600 Ncm)
^ 36 mm long socket
Note:
^ Secure final drive in assembly fixture.
^ Replace both tapered roller bearings together
^ Adjustments are required when replacing components marked with 1).
1. Nut
^ Unscrewing; Refer to Fig. 1
^ Installing; Refer to Fig. 15
^ Measuring friction torque; Refer to Fig. 16
^ Securing; Refer to Fig. 17
2. Driveshaft flange
^ Removing; Refer to Fig. 2
^ Installing; Refer to Fig. 14
3. Seal
^ Pulling out; Refer to Fig. 3
^ Driving in; Refer to Fig. 13
4. 0-ring
^ Always replace
^ Insert with transmission fluid; Refer to Fig. 12
5. Tapered roller bearing Inner race
^ Press out drive pinion; Refer to Fig. 4
^ Pressing on; Refer to Fig. 11
6. Tapered roller bearing outer race
^ Pulling out; Refer to Fig. 5
^ Pressing in; Refer to Fig. 10
7. Spacer sleeve 1)
^ Always replace
8. Final drive housing
9. Shim "ST'
^ Note thickness
^ List of adjustments
10. Double tapered roller bearing outer race
^ Driving out; Refer to Fig. 6
^ Installing; Refer to Fig. 9
11. Double tapered roller bearing Inner race
^ pressing off; Refer to:. Fig. 7
^ pressing on; Refer to Fig. 8
12. Drive pinion 1)
^ Matched to ring gear, always replace together as a set
Fig. 1 Removing drive pinion nut:
^ Thread in two hex head bolts M8 x 30 -A-.
B - 36 mm long socket
When nut is removed, final drive must be supported (e.g. using VAG 1359/2 universal mount together with VAG 1383A transmission hoist).
Fig. 2 Pull off driveshaft flange from drive pinion:
^ Thread two hex head bolts M8 x 30 -A- into flange.
Fig. 3 Pulling out seal for driveshaft flange:
Fig. 4 Pressing out drive pinion from small tapered roller bearing inner race:
Fig. 5 Pulling out tapered roller bearing outer race:
A - Support e.g. Kukko 22/2
B - 21/7 Kukko extractor 46- 58 mm
Fig. 6 Driving out double tapered roller bearing outer race:
^ Check adjustment shims for damage after removing.
Fig. 7 Pressing off large tapered roller bearing inner race from drive pinion:
A - 17/2 Kukko separating tool 22- 115 mm
Fig. 8 Pressing large tapered roller bearing inner race onto drive pinion:
^ Heat inner race to approximately 100°C, place on and then press on.
CAUTION: Wear protective gloves.
Fig. 9 Pressing In double tapered roller bearing outer race:
^ Before installing, install drive pinion shim S3 determined in earlier step.
Note: On 325314 pressure disc, marking "Oben" points toward nut on installation device
Fig.10 Pressing In tapered roller bearing outer race:
^ Install oiled outer race and using VW408A punch and 30-205 thrust pad.
Fig. 11 Pressing on tapered roller bearing Inner race:
^ Insert drive pinion with a new spacer sleeve.
WARNING: Wear protective gloves!
^ 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.
Fig. 12 Replacing O-ring:
^ Insert O-ring with gear oil
Fig. 13 Driving In seal for driveshaft flange:
^ Lightly oil outer circumference of seal.
^ Lubricate area between sealing lip and dust lip with a thin layer of multi-purpose grease.
^ Drive seal in to stop using 3026 pressure piece.
Fig. 14 Installing flange:
^ Drive flange for drive shaft far enough onto drive pinion so that securing nut can be installed.
Fig. 15 Tightening drive pinion nut and adjusting friction torque:
^ Thread in two hex head bolts M8 x 30 -A-.
B - 36 mm long socket
When nut is tightened, final drive must be supported (e.g. using VAG 1359/2 universal mount together with VAG 1383A transmission hoist).
Note: Increase torque slowly and measure friction torque multiple times. 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.16 Measuring friction torque:
With torque gauge, 0 to 600 Ncm, locally available
B - 36 mm socket insert
Note: If necessary use 314" to 112" reducing piece.
^ Adjust to following friction torque:
Fig. 17 Securing drive pinion nut:
^ After nut has been secured, radial run-out at driveshaft flange must be measured.