Pinion Shaft, Removing, Installing, Disassembling and Assembling
Pinion shaft, removing, installing, disassembling and assembling, 01V, 5 SPD. A/T (AWD)
Special tools, testers and auxiliary items required:
^ Puller VW391
^ Thrust plate VW401
^ Thrust plate VW402
^ Punch VW407
^ Punch VW408A
^ Thrust disc VW412
Special tools, testers and auxiliary items required:
^ Support channels VW457
^ Pressing off device VW460
^ Installation ring VW470/1
^ Sleeve VW519
^ Holding fixture VW540
^ Thrust pad 30-205
Special tools, testers and auxiliary items required:
^ Seal installer 2003/3
^ Thrust pad 3005
^ Retainer 3028
^ Thrust pad 3062
^ Drift 3138
^ Seal driver-frt wheel bearing 3143
Special tools, testers and auxiliary items required:
^ Slide hammer-complete set VW771
^ Mandrel 3026
^ Wheel bearing assembly set 3253
^ Engine-/gearbox jack V.A.G 1383 A with universal transmission support V.A.G1359/2
Special tools, testers and auxiliary items required:
^ Needle bearing drift VW295
^ Friction meter VAS 6222
^ Kukko separating tool 22-115mm 17/2
^ Kukko extractor 46/58mm 21/7
^ Kukko support 22/2
^ Sealing grease G052128A1
^ Long socket wrench insert AF 36
^ 2 hex bolts M8x30
Always replace both taper roller bearings together as a set.
Install new tapered roller bearing as supplied and do not use additional oil.
Clamp rear final drive in assembly fixture
^ Adjustment work is necessary when replacing these parts.
1. Nut
^ Unfastening
^ Fastening
^ Measure friction torque while doing so
^ Securing
2. Flange for propshaft Pulling off Installing
3. Seal
^ Pulling out
^ Driving in
4. O-ring
^ Always replace
^ Insert with axle oil
5. Small inner race/tapered roller bearing
^ Pressing off drive pinion
6. Small outer race/tapered roller bearing
^ Pulling out
^ Pressing in
7. Spacer sleeve
^ always replace
8. Rear axle housing
9. Shim S3
^ Note thickness
^ List of adjustments
10. Large outer race/tapered roller bearing
^ Driving out
^ Pulling in
11. Large inner race/tapered roller bearing
^ Pressing off
^ Pressing on
12. Drive pinion
^ is matched to ring gear
^ When replacing, replace completely
Clamp rear final drive in assembly fixture
Removing nut for pinion
A - Screw in 2 hex bolts M8x30
B - Long socket wrench insert AF36
^ When loosening nut, rear final drive must be supported using engine-/gearbox jack V.A.G. 1383 A and universal transmission support V.A.G. 1359/2.
Pulling off flange
A - Screw 2 hex bolts M8x30 in flange.
Pulling out seal for propshaft flange
Pressing off drive pinion from inner race/tapered roller bearing
Pulling off small outer race/tapered roller bearing
A - Kukko support 22/2
B - Internal puller 46 56 mm, e.g. Kukko extractor 46/58mm 21/7
Driving out large outer race/tapered roller bearing
^ After removing, check shims for damage.
Pressing off large tapered roller bearing inner race
A - Separating device 22 115 mm, e.g. Kukko separating tool 22-115mm 17/2
Pressing on large inner race/tapered roller bearing
CAUTION: Wear protective gloves!
^ Heat inner race to approximately 100°C before pressing on.
Pulling in large outer race/tapered roller bearing
^ Insert previously determined adjustment shim S3 for drive pinion.
The writing "oben ("top")" on the thrust pad 3253/4 faces nut for pulling in tool.
Pressing in small outer race/tapered roller bearing
^ Outer race is to be oiled and must be pressed in using needle bearing drift VW295 and thrust pad 30-205.
Inserting small inner race/tapered roller bearing
^ Insert pinion with new spacer sleeve.
CAUTION: Wear protective gloves!
^ Heat inner race to approximately 100°C.
^ Press drive pinion up and press inner race to stop using sleeve 40-21.
Inserting O-ring
^ Insert O-ring with axle oil.
Driving in seal for propshaft flange
^ Coat outer circumference and sealing lips of sealing ring with axle oil.
^ Fill area between sealing lip and dust lip halfway with sealing grease G052128A1.
^ Drive in new seal to stop in rear axle housing, without canting seal.
Installing flange
^ Flanged shaft for propshaft onto pinion far enough until the nut can be installed.
Tightening nut for pinion and adjusting friction torque
A - Screw in 2 hex bolts M8x30.
B - Long socket wrench insert AF36
^ When tightening nut, rear final drive must be supported using engine-/gearbox jack V.A.G. 1383 A and universal transmission support V.A.G. 1359/2.
Increase tightening torque gradually, frequently measuring friction torque. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! A spacer sleeve which has been compressed too much cannot be reused.
Measure friction torque.
To measure friction torque, use friction meter VAS 6222 and long socket insert AF36.
Set following frictional torques:
Secure nut for pinion
^ After the nut has been secured, the radial run-out at propshaft flange must be measured.