Pinion Gear: Service and Repair
Drive Pinion
Special tools, testers and auxiliary items required
• Puller (VW 391)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Support Channels (VW 457)
• Removal Device (VW 460)
• Thrust Ring (VW 470/1)
• Sleeve (VW 519)
• Holding Fixture (VW 540)
• Thrust Pad (30-205)
• Seal Installer (2003/3)
• Thrust Pad (3005)
• Retainer (3028)
• Thrust Pad (3062)
• Drift (3138)
• Seal Driver-Frt Wheel Bearing (3143)
• Slide Hammer - Complete Set (VW 771)
• Mandrel (3026)
• Wheel Bearing Assembly Set (3253)
• Engine/Transmission Jack (V.A.G 1383 A) with Universal Transmission Support (V.A.G 1359/2)
• Needle Bearing Drift (VW 295)
• Friction Meter (VAS 6222)
• Separating Tool (Kukko 17/2)
• Internal Puller (Kukko 21/7)
• Counter-Support (Kukko 22/2)
• Sealing Grease (G 052 128 A1)
• Long Socket (SW 36)
• Two M8 x 30 bolts
Place the Rear Final Drive in the Assembly Stand
Removing the Pinion Nut
A - Installing two M8 x 30 bolts.
B - Long socket (SW 36)
- Support the rear final drive with the (V.A.G 1383 A) and the (V.A.G 1359/2) when loosening the nut.
Removing the Flange
A - Install two M8 x 30 bolts in the flange.
Removing the Seal from the Driveshaft Flange
Removing the Pinion from the Inner Race/Tapered Roller Bearing
Removing the Outer Race/Small Tapered Roller Bearing
A - Counter-support (Kukko 22/2)
B - internal puller 46 to 56 mm, for example, (Kukko 21/7)
Removing Outer Race/Large Tapered Roller Bearing
- Check the shims for damage.
Removing the Inner Race/Large Tapered Roller Bearing
A - separating tool 22 to 115 mm, for example, (Kukko 17/2)
Installing the Inner Race/Large Tapered Roller Bearing
Wear protective gloves.
- Warm the inner race to approximately 100 °C (212 °F).
Installing the Outer Race/Large Tapered Roller Bearing
- Lightly oil the bearing seat inside the rear axle housing.
- Install the shim S3 for the pinion that was selected earlier.
The word oben (top) on the thrust pad (3253/4) faces the nut on the fitting tool.
Installing the Outer Race/Small Tapered Roller Bearing
- Lightly oil the bearing seat inside the rear axle housing.
- Install the outer race using the (VW 295) and the (30-205).
Installing the Inner Race/Small Tapered Roller Bearing
- Install the pinion with a new spacer sleeve.
Wear protective gloves.
- Warm the inner race to approximately 100 °C (212 °F).
- Push the pinion upward and install the inner race all the way using the (40-21).
O-ring, Installing
- Coat the O-ring with gear oil and then install it.
Driveshaft Flange Seal, Installing
- Coat the outer circumference of the seal with gear oil.
- Fill the space between the sealing and dust lips halfway with sealing grease (G 052 128 A1).
- Install the new seal into the rear axle housing. Do not tilt it.
Flange, Installing
- Install the driveshaft flange just far enough onto the pinion until it is possible to install the nut.
Pinion Nut, Tightening and Friction Torque, Adjusting
A - Install two M8 x 30 bolts.
B - Long socket (SW 36)
- Support the rear final drive with the (V.A.G 1383 A) and the (V.A.G 1359/2) when tightening the nut.
Slowly increase the torque and read the friction torque several times. The spacer sleeve must be replaced and the adjustment must be performed again if the specified friction torque is exceeded. A spacer sleeve that has been compressed to far may not be used any longer.
Friction Torque, Measuring
Use the (VAS 6222) and the (SW 36) to measure the friction torque.
Adjust the Following Friction Torques:
* Driven at least 50 km
Pinon Nut, Securing
- Secure the pinion nut.
- Measure the radial run-out on the driveshaft flange. Refer to => [ Radial Run-Out on Flange/Driveshaft, Measuring and Identifying ] Testing and Inspection.