Assembly overview: Disassembling

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.

Fig 1: Identifying Oil Filter, Hole & Special Tool T10108

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set drive pinion housing, as shown in illustration (oil filter = - arrow B - ) from below, to hole - arrow A - marked with the number - 1 - on transmission holder.
Align drive pinion housing to remaining 3 holes and secure.

Fig 2: Unscrewing Twelve-Point Nut For Shaft Bevel Gear Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unscrew twelve-point nut for shaft bevel gear.

A - Toggle on ³ / ₄ drive

NOTE:

Secure shaft bevel gear from falling out while removing twelve-point nut.
The release moment (break open force) is extremely high, use an extension on the toggle if necessary.

Fig 3: Pressing Off Shaft Bevel Gear From Small Tapered Roller Bearing Inner Race Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press off shaft bevel gear from small tapered roller bearing inner race, if necessary. This depends on overlap (press-fit or loose-fit connection).
Remove small tapered roller bearing inner race and spacer sleeve.

Fig 4: Pressing Small Tapered Roller Bearing Outer Race Off Drive Pinion Housing Using Special Tools VW 402 & 3138

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press small tapered roller bearing outer race off drive pinion housing.

Fig 5: Pressing Large Tapered Roller Bearing Outer Race Off Drive Pinion Housing Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press large tapered roller bearing outer race - A - off drive pinion housing.

B - Internal puller 56 to 70 mm , e.g. Kukko 21/8

Fig 6: Pulling Off Large Tapered Roller Bearing Inner Race From Shaft Bevel Gear Using V.A.G 1582 & V.A.G 1582/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off large tapered roller bearing inner race from shaft bevel gear.
Clean threads for nut.

Fig 7: Pulling Shaft Bevel Gear Seals Off Drive Pinion Housing Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull shaft bevel gear seals off drive pinion housing.