Volkswagen Workshop Service and Repair Manuals

Note:

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 39-49

• Taper roller bearing inner race
• ◆ Insert so that the lugs engage in the groove of the taper roller bearing inner race (item 9) => Fig.3
• ◆ Installation position => Fig.4
• ◆ After measuring thickness of shim, fit onto input gear with locking fluid AMV 185 101 A1
• 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
• ◆ Installation position => Fig.4
• ◆ Insert with locking fluid AMV 185 101 A1
• 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.5

Note:

If input gear is renewed, adjust planet carrier => Page 37-97.

→ Fig.1    Pulling off taper roller bearing inner race

• ‒ Place press piece on input gear.

→ Fig.2    Pressing on taper roller bearing inner race

Note:

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 so that the lugs of the inner race engage in the grooves of the opposite inner race (arrow).
  => Fig.4

→ Fig.4    Installation position of taper roller bearing inner race

• ‒ Lug (arrow) must engage in groove of the opposite inner race.

Note:

Taper roller bearings without lugs can also be installed.

→ Fig.5    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.