Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary equipment required

• ◆ Thrust plate VW 401
• ◆ Thrust plate VW 402
• ◆ Press tool VW 407
• ◆ Press tool VW 408 A
• ◆ Press tool VW 412
• ◆ Mounting rails VW 457

• ◆ Drift VW 460/2
• ◆ Tube VW 519
• ◆ Engine and gearbox support VW 540
• ◆ Thrust plate 30-205
• ◆ Inserter ring 2003/3
• ◆ Pinion assembly device 2052/2

• ◆ Thrust plate 3005
• ◆ Thrust pad 3062
• ◆ Drift 3138
• ◆ Assembly device 3253 with 3253/3 and 3253/4
• ◆ Holding tool 3304
• ◆ Engine/gearbox lifter
  V.A.G 1383 A

• ◆ Item 1: Internal puller Kukko 21/7
• ◆ Item 2: Counter support Kukko 22/2
• ◆ Item 3: Separating tool Kukko 17/2
• ◆ Torque gauge 0 ... 600 Ncm
• ◆ Socket, long, 32 A/F

Notes:

• ◆ General repair instructions .
• ◆ Removing thrust tube from rear final drive with final drive installed .
• ◆ Removing thrust tube from rear final drive with final drive removed => Page 39-124.
• ◆ Replace both taper roller bearings together. Use same make if possible.
• ◆ Do not additionally oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.
• ◆ Remove differential => Page 39-126.
• ◆ Adjustments are required when replacing components marked 1) => adjustment overview, Page 39-168.

• Nut
• ◆ Replace
• ◆ Unscrewing => Fig.1 and Fig.2
• ◆ Screwing in => Fig.11
• ◆ Measuring friction torque
  =>Fig.12
• ◆ Securing => Fig.13
• Inner race for small taper roller bearing 1)
• ◆ Pressing out drive pinion => Fig.3
• ◆ Pressing on => Fig.10
• Outer race for small taper roller bearing 1)
• ◆ Pulling out =>Fig.4
• ◆ Pressing in => Fig.9
• Spacer sleeve 1)
• ◆ Replace
• Final drive housing 1)

• Shim "S3"
• ◆ Note thickness
• ◆ Adjustment overview
  .
• Outer race for large taper roller bearing 1)
• ◆ Driving out => Fig.5
• ◆ Inserting => Fig.8
• Inner race for large taper roller bearing 1)
• ◆ Pressing off => Fig.6
• ◆ Pressing on => Fig.7
• Drive pinion1)
• ◆ Is mated with crown wheel, renew together as a set

→ Fig.1    Tool for slackening and tightening drive pinion nut

•     A -    32 mm socket insert

→ Fig.2    Removing nut for drive pinion

• ‒ Fit counterhold 3304 with two hexagon bolts M8 x 30.
• ‒ Final drive must be supported when loosening nut (e.g. using universal support V.A.G 1359/2 in combination with gearbox jack V.A.G 1383 A).

→ Fig.3    Pressing drive pinion out of inner race for small taper roller bearing

→ Fig.4    Pulling out small taper roller bearing outer race

•     B -    Support, e.g. Kukko 22/2
•     B -    Internal puller 46 ... 58 mm, e.g. Kukko 21/7

→ Fig.5    Driving out outer race for large taper roller bearing

• ‒ After removing check shims for damage.

→ Fig.6    Pressing inner race for large taper roller bearing off drive pinion

•     A -    Separating device 22 ... 4.53 in, e.g. Kukko 17/2

→ Fig.7    Pressing inner race for large taper roller bearing onto drive pinion

• ‒ Heat the inner race to approx. 100 °C, position and push to final position.

→ Fig.8    Pulling in outer race for large taper roller bearing

• ‒ Insert predetermined shim "S3" for drive pinion => Page 39-175.

Note:

Inscription "Oben" ("top") with thrust pad 3253/4 faces the nut of the puller.

→ Fig.9    Pressing in small taper roller bearing outer race

• ‒ Oil the outer race and mount it using press tool VW 408 A and thrust plate 30-205.

→ Fig.10    Pressing on small taper roller bearing inner race

• ‒ Insert the new drive pinion with a new spacer sleeve.
• ‒ Heat inner race for small taper roller bearing to approx. 100 °C and fit onto drive pinion.
• ‒ Press up drive pinion and insert bearing with thrust plate 40-21 up to stop.

→ Fig11    Tighten nut for drive pinion and adjusting friction torque

• ‒ Fit counterhold 3304 with two hexagon bolts M8 x 30.
• ‒ Final drive must be supported when tightening nut (e.g. using universal support V.A.G 1359/2 in combination with gearbox jack V.A.G 1383 A).
• ‒ Fit new drive pinion nut.
• ‒ Tighten drive pinion nut just far enough so that no play can be felt at drive pinion.
• ‒ Gradually increase tightening torque, checking friction torque at regular intervals, until specified friction torque is obtained => Fig.12.

Note:

If the specified frictional torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. It is not possible to re-use a spacer sleeve that has been excessively compressed.

→ Fig.12 Measuring frictional torque

•     A -    Torque gauge, commercially available, 0 ... 600 Ncm
•     B -    Extension with 32 mm socket insert

• ‒ The following frictional torques should be set:

    1)    with at least 50 km service

→ Fig.13    Removing nut for drive pinion

• ‒ Peen drive pinion nut with a punch.