Drive Pinion
Drive Pinion
Special tools, testers and auxiliary items required
• Drive flange fitting appliance (VW 391)
• Thrust plate (VW401)
• Thrust plate (VW402)
• Press tool (VW407)
• Press tool (VW408A)
• Press tool (VW412)
• Support rails (VW 457)
• Removal device (VW 460)
• Thrust pieces for drive pinion bearing (VW 470)
• Tube (VW519)
• Engine and gearbox support (VW 540)
• Thrust plate (30-205)
• Installing ring (V.A.G 2003/3)
• Thrust plate (VAS 3005)
• Counter-hold tool (3028)
• Press disk (3062)
• Driver (3138)
• Press tool (3143)
• Multi-purpose tool (VW771)
• Drift (3026)
• Installation tool (3253)
• Engine/transmission jack (VAG1383A)
• Always replace both tapered roller bearings together as a set.
• Install new tapered roller bearings as supplied and do not oil additionally.
• Adjustments are required when replacing components marked 1)=> adjustment overview, => [ Adjustment Overview ] Adjustments.
1 Nut
• Removing => [ Removing nut for drive pinion ]
• Installing => [ Tightening nut for drive pinion and setting
friction torque ]
• Measuring friction torque => [ Measuring friction torque ]
• Securing => [ Securing drive pinion nut ]
2 Flange for drive shaft
• Removing => [ Pulling flange for drive shaft off drive pinion ]
• Installing => [ Installing flange ]
3 Oil seal
• Removing => [ Pulling out oil seal for flange for drive shaft ]
• Driving in => [ Driving in oil seal for flange for drive shaft ]
4 Seal
• Always replace
• Lubricate with transmission oil when installing => [ Installing O-ring ]
5 Inner race for small tapered roller bearing 1)
• Pressing out drive pinion => [ Pressing drive pinion out of inner race for
small tapered roller bearing ]
• Installing => [ Pressing on small tapered roller bearing inner
race ]
6 Outer race for small tapered roller bearing 1)
• Pulling out => [ Pulling out outer race for small tapered roller
bearing ]
• Pressing in => [ Pressing in outer race for small tapered roller
bearing ]
7 Spacer sleeve 1)
• Always replace
8 Final drive housing 1)
9 Shim "S3"
• Note thickness
• Adjustment overview => [ Adjustment Overview ] Adjustments
10 Outer race for large tapered roller bearing 1)
• Driving out => [ Driving out outer race for large tapered roller
bearing ]
• Pulling in => [ Pulling in outer race for large tapered roller
bearing ]
11 Inner race for large tapered roller bearing 1)
• Pulling off => [ Pressing inner race for large tapered roller
bearing off drive pinion ]
• Pressing on => [ Pressing inner race for large tapered roller
bearing onto drive pinion ]
12 Drive pinion 1)
• Is mated with ring gear, always replace together as a set
Removing nut for drive pinion
- Secure final drive on engine/transmission support => [ Rear Final Drive, Securing to Engine/Transmission Support ] Rear Final Drive, Securing to Engine/Transmission Support.
- Thread in two M8 x 30 hex bolts - A -.
- B - = Socket attachment (long) 36 mm A/F
The final drive must be supported when loosening the nut (e.g. using universal transmission attachment (V.A.G 1359/2) in combination with engine/transmission jack (VAG1383A)).
Pulling flange for drive shaft off drive pinion
- Thread two M8 x 30 hex bolts - A - into flange.
Pulling out oil seal for flange for drive shaft
Pressing drive pinion out of inner race for small tapered roller bearing
Pulling out outer race for small tapered roller bearing
- A - = Counter support e.g. Kukko 22/2
- B - = Internal puller 46... 58 mm, e.g. Kukko 21/7
Driving out outer race for large tapered roller bearing
- After removing check shims for damage.
Pressing inner race for large tapered roller bearing off drive pinion
- A - = Separating device 22... 115 mm, e.g. Kukko 17/2
Pressing inner race for large tapered roller bearing onto drive pinion
- Heat bearing to approx. 100° C, place in position and press home.
CAUTION!
Wear protective gloves.
Pulling in outer race for large tapered roller bearing
- Lightly oil bearing seat in housing.
- Insert shim "S3" appropriate for drive pinion => [ Adjustment Overview ] Adjustments.
The identification "oben" (top) on thrust washer (3253)/4 faces nut of puller.
Pressing in outer race for small tapered roller bearing
- Lightly oil bearing seat in housing.
- Insert outer race starting with drift (VW295) and thrust plate (30-205).
Pressing on small tapered roller bearing inner race
- Insert drive pinion with new spacer sleeve.
CAUTION!
Wear protective gloves.
- Heat inner race for small tapered roller bearing to approx. 100° C and place onto drive pinion.
- Press up drive pinion and insert bearing with thrust plate (40-21) onto stop.
Installing O-ring
- Lubricate O-ring with transmission oil and install.
Driving in oil seal for flange for drive shaft
- Lightly oil outer circumference of seal.
- Drive in seal onto stop with drift (3026).
- Half fill volume between sealing lip and dust lip with sealing grease (G 052 128 A1).
Installing flange
- Drive flange for driveshaft onto drive pinion until nut can be installed.
Tightening nut for drive pinion and setting friction torque
- Thread in two M8 x 30 hex bolts - A -.
- B - = Socket attachment (long) 36 mm A/F
The final drive must be supported when tightening the nut (e.g. using universal transmission attachment (V.A.G 1359/2)in conjunction with engine/transmission jack (VAG1383A)).
• Increase tightening torque slowly and check friction torque at regular intervals. If the specified friction torque is exceeded the spacer sleeve must be replaced and the adjustment repeated. A spacer sleeve which has been compressed too much cannot be reused.
Measuring friction torque
With torque gauge, 0 to 600 Ncm, commercially available
- B - = Socket attachment, 36 mm A/F
• Use 3/4 " to 1/2 " adapter if necessary.
Friction torque to be set
* run at least 50 km (30 miles)
Securing drive pinion nut
- After securing nut, measure radial run-out at flange for driveshaft => [ Radial Run-Out at Driveshaft Flange, Measuring ] Radial Run-Out at Driveshaft Flange, Measuring.