Assembly overview: Assembling

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Clean tapered roller bearing outer race seats in drive pinion housing of locking fluid.

Fig 1: Pressing Outer Race For Small Tapered Roller Bearing/Shaft Bevel Gear Into Drive Pinion Housing Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Coat outer race for small tapered roller bearing/shaft bevel gear with locking fluid D 154 000 A1 and press into drive pinion housing.

Fig 2: Pressing Outer Race For Large Tapered Roller Bearing/Shaft Bevel Gear Into Drive Pinion Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Coat outer race for large tapered roller bearing/shaft bevel gear with locking fluid D 154 000 A1 and press into drive pinion housing.

Fig 3: Engaging Seals For Shaft Bevel Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Join new seals for shaft bevel gear as follows:
Place new seals together ( - arrows A - ) with locking lugs - arrows - of seal offset to each other.
Twist seals on opposite side of sides placed together ( - arrow B - ) until locking lugs - arrows - engage into one another - arrow C -.

Fig 4: Inserting Combined Seals For Shaft Bevel Gear Into Drive Pinion Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert combined seals - A - for shaft bevel gear into drive pinion housing.

Installation position:

Seal with smaller outer circumference - arrow - points toward drive pinion housing.

Fig 5: Driving Combined Seals For Shaft Bevel Gear Into Drive Pinion Housing Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive combined seals for shaft bevel gear into drive pinion housing up to stop.

Fig 6: Pressing Large Tapered Roller Bearing Inner Race Onto Shaft Bevel Gear Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press large tapered roller bearing inner race onto shaft bevel gear.
Coat sealing lips of seals with high performance oil G 052 175 A1 for Haldex clutch.
Insert shaft bevel gear into drive pinion housing.
Install new spacer sleeve.

Fig 7: Pressing Small Tapered Roller Bearing Inner Race Onto Shaft Bevel Gear Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press small tapered roller bearing inner race onto shaft bevel gear.

NOTE:

Depending on the overlapping, it may also be possible to slide inner race on shaft bevel gear by hand.

Secure drive pinion housing to transmission holder T10108 .
Coat threads of twelve-point nut with locking fluid D 154 000 A1.
Screw on twelve-point nut for shaft bevel gear.

Fig 8: Screwing On Twelve-Point Nut For Shaft Bevel Gear Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten twelve-point nut to 120 Nm, then measure friction torque , increase tightening torque until specified friction torque is set, if necessary.

A - Toggle on ³ / ₄ drive

Turn torque wrench V.A.G 1332 around toward right to screw on.
Use an adapter of ¹ / ₂ on ³ / ₄ .

NOTE:

Only increase tightening torque slowly and read off friction torque several times while doing this, if specified friction torque is exceeded, spacer sleeve must be replaced and adjustment must be repeated! Any spacer sleeve that has been pressed together too far one time must be replaced.