Pinion Gear: Service and Repair

5 Speed Automatic 01V

Drive pinion, removing and installing, disassembling and assembling
Special tools and equipment
- VAG1383A engine/transmission hoist
- VAG1359/2 universal mount
- VW391 puller
- VW401 thrust plate
- VW402 thrust plate
- VW408A punch
- VW412 punch
- VW457 support channels
- VW460/2 drift
- VW470/1 thrust shell for drive pinion bearing
- VW540 holding fixture
- VW 771 slide hammer-complete set with
- 30-205 thrust pad
- 2003/3 seal installer
- 3005 thrust pad
- 3026 mandrel
- 3028 retainer
- 3062 thrust pad
- 3138 drift
- 3143 seal driver
- 3253 wheel bearing assembly set with 3253/3 and 3253/4
- Kukko17/2 separator
- Kukko21/7 extractor
- Kukko22/2 support
- Torque gauge (0-600 Ncm)
- 36 mm socket (deep)

Notes:
- Secure final drive in assembly fixture.
- Replace both tapered roller bearings together.
- Adjustments are required when replacing components marked with 1).





1. Nut
^ Unscrewing see Fig. 1
^ Installing see Fig. 15
^ Measuring friction torque see Fig. 16
^ Securing see Fig. 17
2. Driveshaft flange
^ Removing see Fig. 2
^ Installing see Fig. 14
3. Seal
^ Pulling out see Fig. 3
^ Driving in see Fig. 13
4. O-ring
^ Replace
^ Insert with transmission fluid see Fig. 12
5. Tapered roller bearing inner race 1)
^ Press out drive pinion see Fig. 4
^ Pressing on see Fig. 11
6. Tapered roller bearing outer race 1)
^ Pulling out see Fig. 5
^ Pressing in see Fig. 10
7. Spacer sleeve 1)
^ Replace
8. Final drive housing 1)
9. Shim "S3"
^ Note thickness
10. Double tapered roller bearing outer race 1)
^ Driving out see Fig. 6
^ Installing see Fig. 9
11. Double tapered roller bearing inner race 1)
^ Pressing off see Fig. 7
^ Pressing on see Fig. 8
12. Drive pinion 1)
^ Matched to ring gear, always replace together as a set





Fig. 1 Removing drive pinion nut
- Thread in two hex head bolts M8 x 30 -A-.
B - 36 mm socket (deep)
- When nut is removed, final drive must be supported (e.g. using VAG1 359t2 universal mount together with VAG1 383A transmission hoist).





Fig. 2 Pull off driveshaft flange from drive pinion
- Thread two hex head bolts M8 x 30 -A- into flange.





Fig. 3 Pull out seal for driveshaft flange





Fig. 4 Pressing out drive pinion from small tapered roller bearing inner race





Fig. 5 Pulling out tapered roller bearing outer race
A- Support e.g. Kukko 22/2
B - 21/7 Kukko extractor 46- 58 mm





Fig. 6 Driving out double tapered roller bearing outer race
- Check adjustment shims for damage after removing.





Fig. 7 Pressing off large tapered roller bearing inner race from drive pinion
A - 17/2 Kukko separating tool 22- 1 15 mm





Fig. 8 Pressing large tapered roller bearing inner race onto drive pinion
Heat inner race to approximately 100°C, place on and then press on.

CAUTION: Wear protective gloves.





Fig. 9 Pressing in double tapered roller bearing outer race
- Before installing, install drive pinion shim S3 determined in earlier step.

Note: On 3253/4 pressure disc, marking "Open" points toward nut on installation device





Fig. 10 Pressing in tapered roller bearing outer race
- The outer race must be oiled and installed using VW408A punch and 30-205 thrust pad





Fig. 11 Pressing on tapered roller bearing inner race
- Insert drive pinion with a new spacer sleeve.

WARNING!: Wear protective gloves!

- Heat up small tapered roller bearing inner race to approximately 100°C and insert on drive pinion.
- Press drive pinion upward and insert bearing up to stop using 40-21.





Fig. 12 Replace O-ring
- Inserting O-ring with gear oil





Fig. 13 Driving in seal for driveshaft flange
- Lightly oil outer circumference of seal.
- Lubricate area between sealing lip and dust lip with a thin layer of multipurpose grease.
- Driving seal in to stop using 3026 pressure piece.





Fig. 14 Installing flange
- Drive flange for drive shaft far enough onto drive pinion so that securing nut can be installed.





Fig. 15 Tightening drive pinion nut and adjusting friction torque
- Thread in two hex head bolts Me x 30 -A-.
B - 36 mm socket (deep)
- When nut is tightened, final drive must be supported (e.g. using VAG1359/2 universal mount together with VAG1 383A transmission hoist).

Note: Increase torque slowly and measure friction torque multiple times. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! Any spacer sleeve that has been pressed together too far one time must be replaced.





Fig. 16 Measuring friction torque
With torque gauge, 0 ... 600 Ncm, locally available
B - 36 mm socket insert

Note: If necessary use 314" to 112" adapter.





- Adjust to following friction torque

1) at least 50 km





Fig. 17 Securing drive pinion nut
- After the nut has been secured, the radial run-out at driveshaft flange must be measured.