Needle Bearing For Spur Gear -2, Replacing

Needle bearing for spur gear -2, replacing, 01V, 5 SPD. A/T (AWD)
^ Observe general repair notes.

Special tools, testers and auxiliary items required:

^ Thrust plate VW402
^ Punch VW408A
^ Sleeve 2080A
^ Hot air blower V.A.G. 1416

Special tools, testers and auxiliary items required
^ Kukko extractor 14.5-18.5mm 21/2

Kukko support 22/122/1:

Removing
^ Remove transfer case.





^ Unbolt rear flanged shaft, secure flanged shaft against turning while doing so.





^ Pull tension nut - A - out of shaft for spur gear-2.
^ Remove bolts - arrows -.
^ Remove guide plate - B - and shim - C -.





^ Attach support - A - at internal extractor - B - as shown and insert shaft for spur gear -2.
^ A - Kukko support 22/122/1.
^ B - Kukko extractor 14.5-18.5mm 21/2.
^ Support the support - A - using thrust plate VW402 and pre-load at nut - 1 - of support.
^ Pull spur gear out and carefully remove it upward.
^ Remove needle bearing securing ring.





^ Slide centering sleeve - 2 - of extractor - B - approximately 4 mm in direction of arrow in order to be able to open pulling hooks of extractor far enough.

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

^ A - - Kukko support 22/122/1
^ B - - Kukko extractor 14.5-18.5mm 21/2
^ Spread extractor - B - into upper lip of needle bearing - 1 - and secure extractor at nut.





^ Install support - A - on extractor - B - as illustrated.
^ Support the support - A - using thrust plate VW402 and pre-load at nut - 3 -of support.
^ Using hot air blower V.A.G. 1416, quickly heat up outside of transfer case in vicinity of needle bearing seat to approximately 80 to 100°C.

CAUTION: Wear protective gloves!

^ Pull needle bearing out quickly.

Installing

Installation is performed in the reverse order of removal. Pay attention to the following:

^ Examine needle bearing seat in transfer case for damage; if necessary rework.
^ Using hot air blower V.A.G. 1416, quickly heat up outside of transfer case in vicinity of needle bearing seat to approximately 80 to 100°C.

CAUTION: Wear protective gloves!





^ Attach new needle bearing and install sleeve 2080A onto new needle bearing - 1 -. The sleeve must be centered when set onto sleeve.
^ Drive needle bearing flush into transfer case to stop using special tool punch VW408A.
^ Install needle bearing securing ring.
^ Carefully insert spur gear-2.





^ Insert guide plate - B - and shim - C - and secure with bolts - arrows -.
^ Press tension nut - A - into shaft of spur gear-2.
^ Bolt on rear flanged shaft.
^ Install transfer case.