Volkswagen Workshop Service and Repair Manuals

Drive pinion and differential do not need to be removed.

• Socket head fastener, 250 Nm
• ◆ Engage parking lock to remove and install
• ◆ Use 22 mm wrench socket
• ◆ Before installing socket head fastener insert axial needle bearing (item 7 )
• Dished washer
• ◆ Curved side faces socket head fastener
• Shim
• ◆ Determining thickness => Adjusting input gear, Page 39-45

• Taper roller bearing inner race
• ◆ After measuring thickness of shim, fit onto input gear with locking fluid AMV 185 101 A1 =>Fig. 3
• Taper roller bearing outer race
• ◆ Drive out with drift
• ◆ Drive in with 30-205
• ◆ Insert with locking fluid AMV 185 101 A1
• Gearbox housing
• Axial needle bearing
• ◆ Install with flat side facing input gear
• ◆ Insert into input gear before installing socket head fastener (item 1)

• Taper roller bearing outer race
• ◆ Drive out with drift
• ◆ Drive in with 30-205 and appropriately long drift
• ◆ Insert with locking fluid AMV 185 101 A1
• Taper roller bearing inner race
• ◆ Pulling off => Fig.1
• ◆ Pressing on =>Fig.2
• ◆ Insert with locking fluid AMV 185 101 A1 =>Fig. 3
• Input gear
• ◆ With impulse wheel for road speed sender -G68-
• ◆ Number of teeth
• ◆ Adjusting
• ◆ If signs of damage exist, always replace input gear and output gear together
• ◆ Removing => Fig.4
• ◆ If input gear is renewed, adjust planet carrier => Page 37-106 .

→ Fig.1     Pulling off taper roller bearing inner race

• ‒ Place press piece on input gear.

→ Fig.2     Pressing on taper roller bearing inner race

A press piece must be placed below the hub of the input gear to avoid damaging the input gear.

→ Fig.3     Inserting taper roller bearing inner race

• ‒ Insert taper roller bearing inner race with AMV 185 101 A1.

→ Fig.4     Removing input gear

• ‒ Insert socket head fastener without dished washer, shim and axial needle bearing far enough for a gap size a = 3 mm to exist between socket head fastener and taper roller bearing inner race.
• ‒ Drive out input gear with VW 771 as far as the stop of the taper roller bearing inner race.
• ‒ Remove VW 771 and take out input gear.