Drive Axle Bearing, Replacing

• Clutch, engaging bearing and slave cylinder removed. Refer to DUAL CLUTCH, REMOVING AND INSTALLING .

-- With the Puller - Crankshaft/Power Steering Seal:T20143  carefully remove the seal -arrow- from the housing.

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-- A waved washer -arrow- is located behind the seal, it does not need to be replaced.

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• Pay attention to the installation position of the waved washer!

Drive out the input shaft needle bearing 1.

Fig 1: Drive Out the Input Shaft Needle Bearing -1-

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2 -  Counterhold Tool:T10114 

• Remove the locking ring  OVERVIEW - CLUTCH HOUSING beforehand.

Make sure that the Counterhold Tool:T10114  -2- only in contact with the needle bearing -arrows- and not the housing edges.

Drive in the input shaft needle bearing 1

Fig 2: Drive in the Input Shaft Needle Bearing -1-

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2 -  Bearing Installer - Wheel Bearing/Ball Bearing:3074 

3 -  Bearing/Bushing Installer - Multiple Use:VW295A 

• Installation position: labeling of the bearing -arrow A- (thicker wall thickness -arrow B-) points to the Bearing Installer - Wheel Bearing/Ball Bearing:3074  -2-.

-- Then insert the needle bearing circlip  OVERVIEW - CLUTCH HOUSING.

-- Install the input shaft seal. Refer to INPUT SHAFT SEAL, REPLACING, CLUTCH HOUSING .

Slide off the output gear 1 of the spur gear unit from the pinion.

Fig 3: Slide off the Output Gear -1- of the Drive Wheel from the Pinion.

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• Remove the hydraulic pressure reservoir. Refer to Vehicles with Self-Locking Center Differential .
• Beforehand, remove the circlip  OVERVIEW - CLUTCH HOUSING from the pinion.

2 -  Press Piece - Output Shaft Gear/Final Drive Gear:3002 

3 -  Puller (Kukko 18/2):VAS 251 419 

4 -  M14 x 1.5 Nut or M14 x 1.5 Wheel Nut

-- Attach the Puller -3- to the output gear -1- for the spur gear unit using the nuts -4-.

-- Warm the output gear -1- for the spur gear unit to approximately 100 °C (212 °F) using the Hot Air Blower.

-- Counterhold on the Puller -arrow- when removing.

Detach the parking lock gear

Fig 4: Detach the Parking Lock Gear

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• Vehicles with self-locking center differential: remove inner output shaft. Refer to Inner Output Shaft Roller Bearing, Removing, Vehicles with Self-Locking Center Differential .

-- Release the lever for the parking lock -2- in the -direction of the arrow-, using pliers.

-- Remove the parking lock gear -1- upward from the pinion -3-.

Press on the spur gear unit output gear 5, vehicles without electric drive motor

Fig 5: Install the Drive Wheel Output Gear -5-

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1 -  Spindle from Puller (Kukko 18/2):VAS 251 419 

2 -  Nut

3 -  Thrust bearing from Subframe Bushing Tool Kit:3301 

4 -  Press Piece - Trailing Arm:2010 

• Beforehand, place the gear for the parking lock  OVERVIEW - CLUTCH HOUSING on the pinion.
• Installation position of the gear for the parking lock: the high collar points to the spur gear unit output gear.
• Output gear installation position: the reinforcement ridges -arrow A- face upward.

-- Install the nut -6- (M12) with the washer until the threads are flush.

• The total height of the nut -6- and the washer must not be more than 12 mm.
• The spindle -1- and the nut -6- must not contact the clutch housing -arrow C-.
• Vehicles with self-locking center differential: pay attention to the inner self-locking center differential!

-- Warm the output gear of the spur gear unit -5- using the Inductive Heater:VAS 6414  to approximately 120 °C (248 °F) and on the pinion in the installation position.

-- Then press on over the nut -2- of the output gear of the spur gear unit -5-. At the same time counterhold on the hex fitting -arrow B- of the spindle -1-.

Press on the spur gear unit output gear 6, vehicles with electric drive motor

Fig 6: Press on the spur gear unit output gear -6-, vehicles with electric drive motor

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1. Nut, locked (quantity 2)
2. Threaded spindle M16 with a length of at least 450 mm
3. Nut
4. Thrust bearing from Subframe Bushing Tool Kit:3301 
5. Press Piece - Trailing Arm:2010 

• Beforehand, place the gear for the parking lock  OVERVIEW - CLUTCH HOUSING on the pinion.
• Installation position of the gear for the parking lock: the high collar points to the spur gear unit output gear.
• Output gear installation position: the reinforcement ridges -arrow A- face upward.

-- Install the nut -7- (M16) with the washer until the threads are flush.

• The total height of the nut -7- and the washer must not be more than 12 mm.
• The threaded spindle -2- and the nut -7- must not contact the clutch housing -arrow C-.
• Vehicles with self-locking center differential: pay attention to the inner self-locking center differential!

-- Warm the output gear of the spur gear unit -6- using the Inductive Heater:VAS 6414  to approximately 120 °C (248 °F) and on the pinion in the installation position.

-- Then press on over the nut -3- of the output gear of the spur gear unit -6-. At the same time counterhold at the locked nuts -arrow B- of the threaded spindle -1-.

Continuation for all vehicles

Determine the circlip for the output gear of the spur gear unit on the pinion

Fig 7: Determining Circlip

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TIP:

• The output gear for the spur gear unit is pressed all the way on.
• The illustration shows a different component. However, determining the circlip is identical.

-- Determine the thickest (but still usable) circlip and insert it. For the part number, refer to the appropriate Electronic Parts Information.

The following circlips are available: