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 ) Circlip 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 ) Circlip.

-- 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 ) Circlip 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.

CAUTION:

Risk of damaging the transmission housing.

The Puller must not contact a housing rib with the nuts -4-.

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

Beforehand, place the gear for the parking lock ) Parking Lock Gear 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 Parts Information.

The following circlips are available:

Circlip thickness (mm)
3.85	3.90	3.95
4.00	4.05	4.1