Audi Workshop Service and Repair Manuals

Notes:

• ◆ Drive pinion and crown wheel may only be replaced together.
• ◆ If the drive pinion cover, spacer tube, input gear or parking lock gear are renewed, re-determine thickness of shim "S4" for the drive pinion .
• ◆ If the taper roller bearings or the bush for the drive pinion are renewed, re-determine thickness of shims "S3" and "S4" for the drive pinion => Page 39-78.
• ◆ If the drive pinion (with crown wheel) is renewed, re-determine thickness of shims "S3" and "S4" and shims "S1" and "S2" (for final drive) => Pages 39-92.
• ◆ Always replace all taper roller bearings on same shaft together.
• ◆ The O-ring -Item 39-30 can be replaced with the gearbox installed. For other repair work the gearbox has to be removed.
• ◆ Oil seal for drive pinion, -Item 39-32, must be installed dry. Do not oil or grease sealing lips.
• ◆ Adjustments are required when replacing components marked 1)
  =>Adjustment overview Page 39-64.

• Drive pinion1)
• ◆ To remove, remove differential
  
• ◆ Is mated to crown wheel. Renew complete drive set if damaged.
• ◆ Number of teeth => from page 00-3
• ◆ Adjusting crown wheel and drive pinion => Page 39-70
• ◆ Inserting
  => Fig.39-36
• Taper roller bearing inner race1)
• ◆ WIth roller cage
• ◆ Pulling off
  => Fig.39-36
• ◆ Pressing on
  =>Fig.39-37
• Bush for drive pinion1)
• ◆ Pulling off
  => Fig.39-36
• ◆ Pressing on
  =>Fig.39-37

• Taper roller bearing outer race1)
• ◆ Drive out with 3138
• ◆ Pulling in
  => Fig.39-37
• Shim "S3"
• ◆ Note thickness
• ◆ Adjustment overview
  => Page 39-64
• Sealing cap
• ◆ Driving out
  => Fig.39-40
• ◆ Driving in
  => Fig.39-40
• Hexagon nut
• ◆ Renew
• ◆ Engage parking lock to slacken or tighten
• ◆ Tightening torque => Page 39-78, Adjusting drive pinion
• ◆ Secure by peening
  =>Fig.39-39

• Taper roller bearing inner race1)
• ◆ With roller cage
• Taper roller bearing outer race1)
• ◆ Drive out with drift
• ◆ Pressing in
  =>Fig.39-39
• Bolt - 25 Nm
• ◆ Apply sealant AMV 188 200 03 when installing
• ◆ Tighten in stages and diagonally
• Cover for drive pinion1)
• O-ring
• ◆ Renew
• ◆ Can be renewed with gearbox installed

• Spacer tube1)
• ◆ Install with larger shoulder facing toward output gear
• Shim "S4"
• ◆ Note thickness
• ◆ Adjustment overview
  => Page 39-64
• Output gear1)
• ◆ Number of teeth =>from Page 00-3
• ◆ Pulling off
  => Fig.39-38
• ◆ Install heated
• ◆ If signs of damage exist, always replace input gear and output gear together
• ◆ Install with raised collar facing toward parking lock gear

• Parking lock gear1)
• ◆ Install with rounded side facing toward output gear
• Oil seal for drive pinion
• ◆ Drive out with drift
• ◆ Renew
• ◆ Oil seal should be installed dry
• ◆ Do not oil or grease sealing lips
• ◆ Driving in
  => Fig.39-38

Special tools and workshop equipment required

• ◆ Drift VW 295
• ◆ Thrust plate VW 402
• ◆ Press tool VW 407
• ◆ Press tool VW 412
• ◆ Press tool VW 433
• ◆ Installing and removing tool VW 459

• ◆ Threaded spindle VW 517
• ◆ Thrust plate 30-11
• ◆ Thrust plate 30-205
• ◆ Press tool 40-20
• ◆ Support bridge 2011
• ◆ Tube 2040

• ◆ Thrust pad 3062
• ◆ Drift 3138
• ◆ Assembly sleeve 3187
• ◆ Tapered roller bearing puller V.A.G 1582
• ◆ Adapter 1582/6

→ Fig.1    Inserting drive pinion

Use assembly sleeve 3187 to avoid damaging sealing lips when inserting drive pinion.

•     A -    Assembly sleeve 3187

→ Fig.2    Pulling off taper roller bearing inner race with bush for drive pinion

→ Fig.3    Pressing on taper roller bearing inner race with bush for drive pinion

→ Fig.4    Pulling taper roller bearing outer race into gearbox housing

→ Fig.5    Driving in drive pinion oil seal onto stop

Note:

Oil seal should be installed dry; do not grease or oil sealing lips.

• ‒ Drive in seal as far as stop.
• ‒ Install with raised collar (inner side) facing toward parking lock gear

→ Fig.6    Pulling off output gear from drive pinion

•     A -    Kukko 20-10 and pulling hook Matra V 172

→ Fig.7    Pressing in taper roller bearing outer race

→ Fig.8    Peening hexagon nut

• ‒ Secure collar of hexagon nut by peening against flat face of drive pinion -arrow- using a punch.

→ Fig.9    Driving out cover

The cover is damaged when it is removed.

→ Fig.10    Driving in cover

• ‒ Drive in new cover with 40-20 as far as stop.