Audi Workshop Service and Repair Manuals

Removing and installing pinion shaft; dismantling and assembling pinion shaft

Special tools and workshop equipment required

t	Drive flange installing tool -VW 391-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Support rails -VW 457-

t	Removing tool -VW 460-

t	Assembly ring -VW 470/1-

t	Tube -VW 519-

t	Engine and gearbox support -VW 540-

t	Thrust plate -30-205-

t	Installing ring -2003/3-

t	Thrust plate -3005-

t	Counterhold tool -3028-

t	Thrust pad -3062-

t	Drift -3138-

t	Drift sleeve -3143-

t	Multi-purpose tool -VW 771-

t	Punch -3026-

t	Assembly tool -3253-

t	Engine and gearbox jack -V.A.G 1383 A- with universal gearbox support -V.A.G 1359/2-

t	Drift -VW 295-

t	Friction gauge -VAS 6222-

t	Splitter -Kukko 17/2-

t	Internal puller -Kukko 21/7-

t	Counter-support -Kukko 22/2-

t	Sealing grease -G 052 128 A1-

t	Socket (long) -SW 36-

t	2 x Hexagon bolts M 8 x 30

Clamping rear final drive to assembly stand

Removing nut for pinion shaft A - Screw in 2 hexagon bolts M 8 x 30. B - Socket (long), 36 mm –  When loosening nut, rear final drive must be supported with engine and gearbox jack -V.A.G 1383 A- and universal gearbox support -V.A.G 1359/2-.

Pulling off flange A - Screw 2 hexagon bolts M 8 x 30 into flange.

Pulling out oil seal for propshaft flange

Pressing pinion shaft out of tapered roller bearing inner race

Pulling out small tapered roller bearing outer race A - counter-support -Kukko 22/2- B - internal puller 46 … 56 mm, e.g. -Kukko 21/7-

Driving out large tapered roller bearing outer race –  After removing, check shims for damage.

Pressing off large tapered roller bearing inner race A - splitter 22 … 115 mm, e.g. -Kukko 17/2-

Pressing on large tapered roller bearing inner race   WARNING Wear protective gloves. –  Heat inner race to approx. 100°C before installing.

Pulling in large tapered roller bearing outer race –  Lightly oil bearing seat in rear final drive housing. –  Fit previously determined shim ”S3” for pinion shaft. Lettering “oben” (top) on thrust plate -3253/4- faces nut of puller.

Pressing in small tapered roller bearing outer race –  Lightly oil bearing seat in rear final drive housing. –  Use drift -VW 295- and thrust plate -30-205- for pressing in outer race.

Installing small tapered roller bearing inner race –  Insert pinion shaft with new spacer sleeve.   WARNING Wear protective gloves. –  Heat inner race to about 100°C. –  Press pinion shaft up and press inner race fully home onto stop with press tool -40-21-.

Installing O-ring –  Lubricate O-ring with gear oil when installing.

Driving in oil seal for propshaft flange –  Lightly lubricate outer circumference of oil seal with gear oil. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Drive in new seal onto stop in rear final drive housing (take care to keep seal straight).

Installing flange –  Drive propshaft flange onto pinion shaft until the securing nut can be fitted.

Tightening nut for pinion shaft and setting friction torque A - Screw in 2 hexagon bolts M 8 x 30. B - Socket (long), 36 mm –  When tightening nut, rear final drive must be supported with engine and gearbox jack -V.A.G 1383 A- and universal gearbox support -V.A.G 1359/2-. Only increase tightening torque slowly. Stop and and check friction torque several times. If the specified friction torque is exceeded, the spacer sleeve must be renewed and the adjustment procedure repeated. A spacer sleeve which has been compressed too much cannot be re-used.

Measuring friction torque Use bearing preload gauge -VAS 6222- and socket (long) -SW 36- for measuring friction torque. Set friction torque as follows:

New bearings	Used bearings → Note
150 … 200 Ncm	30 … 60 Ncm

1)  run at least 50 km (30 miles)

Securing nut for pinion shaft –  Secure nut for pinion shaft. –  Measure radial run-out at flange for propshaft → Chapter.