Drive Pinion, Disassembling And Assembling

Special tools and workshop equipment required

Press Plate :VW 402
Press Plate :VW402
Press Piece - Multiple Use :VW412
Thrust Piece
Extracting Tool - Thrust Piece :T40413/13
Inductive Heater :VAS 6414
Separating Tool
Splitter (Kukko 17/2) :VAS 251 411
Circlip Pliers :VAS 5503A

Disassembling

Circlip from the pinion, removing

-- Push the preload sleeve together until the circlip -1- can be removed from the groove of the pinion -2-.

Fig 1: Remove the Circlip for the Preload Sleeve -1- from the Pinion

Courtesy of AUDI OF AMERICA, LLC

Conditions

Position the Thrust Piece :T40413/13 on the pinion -2- so that the groove on the circlip -1- is in the center of the large opening on the Thrust Piece.

Press Piece - Multiple Use :VW412
Extracting Tool - Thrust Piece :T40413/13
Circlip Pliers :VAS 5503A
Press Plate :VW 402

Double Angular Contact Ball Bearing, Removing

-- Secure the pinion -3- from falling.

Fig 2: Remove the Double Angular Contact Ball Bearing -2-

Courtesy of AUDI OF AMERICA, LLC

Splitter (Kukko 17/2) :VAS 251 411

Conditions

If the lower inner race of the double angular contact ball bearing stays on the pinion, it must be removed separately using the Splitter, for example KUKKO 17-2 :VAS 251 411 -1-.

Inner race of the double angular contact ball bearing, pressing off

-- Secure the pinion from falling.

Fig 3: Remove the Inner Race of the Double Angular Contact Ball Bearing -2-

Courtesy of AUDI OF AMERICA, LLC

-- Secure the Separating Tool -1- in the groove of the inner races -arrow-.

Assembling

Double angular contact ball bearing on the pinion, pressing on

-- Warm the double angular contact ball bearing using the Inductive Heater :VAS 6414 to approximately 100 °C (212 °F) and press in all the way.

Fig 4: Press the Double Angular Contact Ball Bearing -1- on the Pinion

Courtesy of AUDI OF AMERICA, LLC

Conditions

Installation position of the double angular contact ball bearing -1- : the groove all around -all arrow- points upward to the pressing tool.

Circlip on the pinion, installing (vehicles with preload sleeve)

-- Fist install a new preload sleeve -2- in the installation position.

Fig 5: Install the Circlip -1- on the Pinion as Follows:

Courtesy of AUDI OF AMERICA, LLC

Conditions

Installation position of the preload sleeve: the higher collar -arrow- points to the circlip -1-.
Push a new circlip -1- all the way on the preload sleeve.

CAUTION:

Risk of damaging the preload sleeve

- Carefully raise the force only until it engages.

- If the preload sleeve is pressed together too much, it can loose its tension force and must be replaced.

-- Carefully press the preload sleeve -1- together using the shop press.

Fig 6: Bring the Circlip for the Preload Sleeve -2- into Installation Position

Courtesy of AUDI OF AMERICA, LLC

Conditions

Position the Thrust Piece :T40413/13 on the pinion so that the groove on the circlip -2- is in the center of the small opening on the Thrust Piece.

Press Piece - Multiple Use :VW412
Extracting Tool - Thrust Piece :T40413/13
Press Plate :VW402

Vehicles with final drive reinforcement

-- Press together the double angular contact ball bearing so far, until the sleeve -3- lowered so far that the circlip -2- can be inserted into the groove.

Fig 7: Bring the circlip for the pinion -2- into installation position

Courtesy of AUDI OF AMERICA, LLC

Conditions

Position the Thrust Piece :T40413/13 -B- on the pinion -1- so that the groove on the circlip -2- is in the center of the large opening on the Thrust Piece.

Press Piece - Multiple Use :VW412
Extracting Tool - Thrust Piece :T40413/13
Screwdriver
Press Plate :VW 402

-- Using a screwdriver -C- the position of the circlip -2- in the groove can be corrected through the hole in the Extracting Tool - Thrust Piece :T40413/13 .

Continuation for all vehicles

-- The circlip must engage audibly in the pinion groove all around.

-- After pressing check that the circlip is in the groove all around.