Volkswagen Workshop Service and Repair Manuals

Assembly sequence - bevel gear mounting

Special tools and workshop equipment required

t	Drift sleeve -VW 192-

t	Support clamp -VW 313-

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Thrust piece -VW 432-

t	Thrust pad -VW 510-

t	Multipurpose tool -VW 771-

t	Puller hooks -VW 771/37-

t	Support -40 - 103-

t	Tube -2010-

t	Thrust piece -2050-

t	Tube -3118-

t	Drift -3138-

t	Assembly tool -3253/1-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/1-

t	Torque wrench -V.A.G 1601-

t	Gearbox support -T10108-

t	Assembly tool -T10114-

t	Internal puller -1 - Kukko 21/8-

t	Torque wrench -V.A.G 1332-

t	Torque gauge, 0...600 Ncm, commercially available

Pinion housing removed from rear final drive housing → Chapter. Dismantling

–  Attach pinion housing to gearbox support from below as shown in figure (oil filter = -arrow B-) at the hole marked -1--arrow A-. –  Then align pinion housing with remaining 3 holes and secure.

–  Remove 12-point nut for shaft bevel gear. A -  3/4” drive ratchet   Note t  When removing 12-point nut, secure shaft bevel gear against falling out. t  The loosening torque is very high. If necessary, add an extension to the ratchet. –  Remove inner race for small tapered roller bearing and spacer sleeve.

–  Press small tapered roller bearing outer race out of pinion housing.

–  Press large tapered roller bearing outer race -A- out of pinion housing. -B-Internal puller -Kukko 21/8- 56 … 70 mm

–  Pull large tapered roller bearing inner race off shaft bevel gear. –  Clean thread on nut.

–  Pull shaft bevel gear oil seal out of pinion housing. Assembling   Note Clean locking fluid from seats for tapered roller bearing outer races in pinion housing.

–  Coat outer race for small shaft bevel gear with locking fluid Loctite 638 and press into pinion housing.

–  Coat outer race for large shaft bevel gear with locking fluid Loctite 638 and press into pinion housing.

–  Assemble new oil seals for shaft bevel gear as follows: –  Put new oil seals together -arrows A- with locking lugs -arrows- of oil seal offset from each other. –  With the seals together, twist in opposite directions -arrow B- until locking lugs -arrows- engage in each other -arrow C-.

–  Insert assembled oil seals -A- for shaft bevel gear in pinion housing. Installation position: Seal with smaller outer diameter -arrow- faces pinion housing.

–  Drive assembled oil seals for shaft bevel gear into pinion housing to stop. –  Secure pinion housing on gearbox support -T10108- → Anchor.

–  Press large tapered roller bearing inner race onto shaft bevel gear. –  Moisten sealing lips of oil seals with high-performance oil for Haldex coupling -G 052 175 A1-. –  Insert shaft bevel gear in pinion housing. –  Install new spacer sleeve. –  Set small tapered roller bearing inner race onto shaft bevel gear. –  Coat thread of 12-point nut with Loctite 638. –  Screw on 12-point nut for shaft bevel gear.

–  Tighten 12-point nut to 120 Nm, measure friction torque → Anchor and if necessary increase tightening torque until specified friction torque is attained. A -  3/4” drive ratchet –  Turn torque wrench -V.A.G 1332- to right to tighten. –  Use 1/2” to 3/4” adapter.   Note Increase torque setting 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. Following friction torques are to be set:

New bearings	Used bearings → Note
200 ... 250 Ncm	30 ... 50 Ncm

1)  run for at least 50 km (30 miles)

–  Measure friction torque. A -  Torque gauge, 0 … 600 Ncm, commercially available B -  1/2” to 3/4” adapter