Audi Workshop Service and Repair Manuals

Dismantling and assembling pinion shaft

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Support rails -VW 457-

t	Multi-purpose tool -VW 771-

t	Tube -32 - 109-

t	Drift sleeve -40 - 21-

t	Punch -3013-

t	Tube for wheel bearing -3345-

t	Adapter -V.A.G 1582/7-

t  Sleeve -T40103-

t  -1-Internal puller -Kukko 21/2-

Pulling out needle bearing for flange shaft in pinion shaft A -  Internal puller 12 ... 14.5 mm, e.g. -Kukko 21/1-

Driving in needle bearing for flange shaft in pinion shaft until flush Install needle bearing so the lettering (side with thicker metal) faces towards the punch -3013-.

Pressing off tapered roller bearing inner race –  Remove circlip and washer before pressing off. –  Set up adapter -V.A.G 1582/7- behind bearing rollers. –  Then carefully press off tapered roller bearing inner race. –  Remove shim “S5” from pinion shaft.   Note Tapered roller bearing inner race can also be pressed off together with the double angular contact ball bearing → Fig..

Pressing off double angular contact ball bearing

Pressing on double angular contact ball bearing l  Installation position: shoulder on bearing outer race faces towards pinion gear. –  Place smaller diameter of tube -VW 415 A- on bearing inner race. –  Press on double angular contact ball bearing as far as it will go. l  Now re-determine thickness of shim “S5” → Chapter if pinion shaft (final drive gear set) is being renewed.

Pressing on tapered roller bearing inner race –  First place shim “S5” onto double angular contact ball bearing on pinion shaft. –  Then heat inner race to approx. 100 °C and press on. –  Then position washer -A- → Fig. onto inner race. –  Afterwards determine required thickness of circlip -B- → Fig. and insert.

Determining thickness of circlip -B- –  Determine the thickest circlip that will just fit and install it. For Part No. refer to → Electronic parts catalogue “ETKA”. The following circlips are available:

Circlip thickness (mm)
1.50	1.90	2.30
1.55	1.95	2.35
1.60	2.00	2.40
1.65	2.05	2.45
1.70	2.10	2.50
1.75	2.15	2.55
1.80	2.20	2.60
1.85	2.25