Drive Pinion, Removing, Installing, Disassembling and Assembling
Drive pinion, removing, installing, disassembling and assembling - 6 Spd. Manual Transmission 01E
Special tools, testers and auxiliary items
^ Press plate VW 401
^ Press plate VW 402
^ Press tool VW 407
^ Press tool VW 408 A
^ Press tool VW 412
^ Support rails VW 457
^ Mandrel VW 460/2
^ Tube VW 519
^ Engine and transmission support VW 540
^ Thrust plate 30-205
^ Installing ring 2003/3
^ Pinion assembly appliance 2052/2
^ Thrust plate 3005
^ Thrust pad 3062
^ Drift 3138
^ Fitting appliance 3253 with 3253/3 and 3253/4
^ Retainer 3304
^ Engine/transmission jack V.A.G 1383 A
^ Universal support V.A.G 1359/2
^ Separating tool Kukko 17/2
^ Two-arm puller Kukko 21/7
^ Counter-support Kukko 22/2
^ Torque gauge 0-600 Ncm
^ Socket attachment (long), 32 mm A/F
Note:
^ Observe general repair instructions.
^ Removing drive flange housing from rear final drive with final drive installed.
^ Removing drive flange housing from rear final drive with final drive removed.
^ Replace both tapered roller bearings together. Use same make if possible.
^ Do not additionally oil new tapered roller bearings for friction torque measurement. The bearings have already been treated with a special oil by the manufacturer.
^ Removing differential.
^ Adjustments are required when replacing components marked with a 1)
1 - Nut
^ Always replace
^ Measuring friction torque
^ Secure
2 - Inner race for small tapered roller bearing 1)
^ Press out drive pinion
3 - Outer race for small tapered roller bearing 1)
4 - Spacer sleeve 1)
^ Always replace
5 - Final drive housing 1)
6 - Shim "S3"
^ Note thickness
^ Adjust
7 - Outer race for large tapered roller bearing 1)
8 - Inner race for large tapered roller bearing 1)
9 - Drive pinion 1)
^ Is mated with ring gear, always replace together as a set
Tools for loosening and tightening drive pinion nut
A - Socket (32 mm)
Remove nut for drive pinion
- Secure retainer 3304 with two M8 x 30 hex bolts.
- Support final drive when loosening nut (e.g. using universal support V.A.G 1359/2 in combination with transmission jack V.A.G 1383 A).
Press drive pinion out of inner race for small tapered roller bearing
Pull 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.
Press inner race for large tapered roller bearing off drive pinion
A - Separating device 22-115 mm, e.g. Kukko 17/2
Press inner race for large tapered roller bearing onto drive pinion
CAUTION:
Wear protective gloves.
- Heat bearing to approx. 100° C, fit in position and press home.
Pull in outer race for large tapered roller bearing
- Insert predetermined shim "S3" for drive pinion.
Note:
Inscription "Oben" faces the nut of the puller with thrust washer 3253/4.
Press in outer race for small tapered roller bearing
- Lubricate outer race with oil and fit using press tool VW 408 A and thrust plate 30-205.
Press on small tapered roller bearing inner race
CAUTION:
Wear protective gloves.
- Insert drive pinion with new spacer sleeve.
- Heat inner race for small tapered roller bearing to approx. 100° C and fit onto drive pinion.
- Press up drive pinion and insert bearing with thrust plate 40-21 onto stop.
Tighten nut for drive pinion and measuring friction torque
- Secure retainer 3304 with two M8 x 30 hexagon bolts.
- Support final drive when tightening nut (e.g. using universal support V.A.G 1359/2 in conjunction with transmission jack V.A.G 1383 A).
- Fit a new drive pinion nut.
- Tighten drive pinion nut just far enough so that no play can be felt at drive pinion.
- Gradually increase tightening torque, checking friction torque at regular intervals, until specified friction torque is obtained.
Note:
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
A - Torque gauge, commercially available, 0-600 Ncm
B - Extension with 32 mm socket
- The following friction torques should be set:
1) run at least 50 km (30 miles)
Securing drive pinion nut
- Peen drive pinion nut with punch.