Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Press plate VW 402
• ◆ Press tool VW 408 a
• ◆ Press tool VW 409
• ◆ Press tool VW 412
• ◆ Tube VW 415 a
• ◆ Extractor lever VW 681
• ◆ Press tool 30-11
• ◆ Extension 30-23
• ◆ Sleeve 30-100
• ◆ Press tool 40-20
• ◆ Tube 2040
• ◆ Press tool 2050

• ◆ Press tool 3124
• ◆ Drift 3138
• ◆ Socket 3156
• ◆ Drift sleeve 3158
• ◆ Torque wrench V.A.G 1332
• ◆ Puller V.A.G 1582
• ◆ Grip piece V.A.G 1582/1

Rear axle housing has been removed from bevel gear housing .

• ‒ Take bevel gear with input shaft out of bevel gear housing.
• ‒ Pull seal out with VW 681.
• ‒ → Remove hexagon nut for shaft bevel gear.

• A - Ring spanner SW41
• B - Torque wrench - turn clockwise to remove

• ‒ → Pressing small taper roller bearing inner race off shaft bevel gear.

Notes:

• ◆ Lower edge of bevel gear housing is located in pressure plate VW 402 rear cut out.
• ◆ After pressing out check housing joint flange for damage.

• ‒ → Drive small taper roller bearing outer race out of bevel gear housing.

• ‒ → Drive large taper roller bearing outer ring out of bevel gear housing.

• A - Internal puller 56 ... 70 mm, e.g. Kukko 21/8
• Previously:
  Push driver 3138 through large taper roller bearing outer race hole in the direction of seal seat, then expand and drive outer race out against foot of internal puller -A-.

• ‒ Remove shim S3.

• ‒ → Pulling large taper roller bearing inner race off shaft bevel gear.

For vehicles with 6 cylinder injection engine:

• ‒ First place press piece 30-11 on shaft bevel gear.

• ‒ Press large taper roller bearing inner race on shaft bevel gear with tube VW 415 a.
• ‒ → Pressing shaft bevel gear large taper roller bearing outer race in bevel gear housing.

• First insert shim S3.

• ‒ → Pressing shaft bevel gear small taper roller bearing outer race in bevel gear housing.

Notes:

• ◆ Step of tube VW 415 a to pressure plate VW 402.
• ◆ Place bearing outer race on tube VW 415a.
• ◆ Do not cant when pressing in.

• ‒ Fit shaft bevel gear in bevel gear housing.
• ‒ Place on a new distance sleeve.
• ‒ → Lightly press small taper roller bearing inner race onto shaft bevel gear.

• The distance sleeve must not be pressed together whilst pressing on.

• ‒ Fit hexagon nut to shaft bevel gear.
• ‒ → Tighten hexagon nut to 120 Nm, then measure friction torque => Page 39-136 , if necessary increase tightening torque further until the correct friction torque is set.

• A - Ring spanner 41 mm AF
• B - Torque wrench - to screw on turn anti-clockwise

Note:

Increase tightening torque slowly and check friction torque at regular intervals. If the prescribed friction torque is exceeded, the spacer sleeve must be renewed and the adjustment repeated. A spacer sleeve which has been compressed too much cannot be reused.

Set friction torque as follows:

     1)     run at least 50 km (30 miles)

• ‒ → Measure friction torque.

• With torque gauge, 0 ... 600 Ncm, commercially available

• ‒ Drive new seal in onto stop with sleeve 3158. When doing this do not cant seal.