5-speed manual gearbox 01A, all-wheel drive — Removing and installing pinion shaft and dismantling and assembling — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

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• The rear final drive must be supported when nut is loosened (e.g. with universal gearbox mountingV.A.G 1359/2 in conjunction with engine and gearbox jackV.A.G 1383 A).
• Inscription "„Oben“" (up) on thrust pad3253/4 faces nut of fitting tool.
• The radial run-out at propshaft flange must be measured and marked .

📋 Procedure

1. Screw in two M8×30 hexagon bolts(A).
2. The rear final drive must be supported when nut is loosened (e.g. with universal gearbox mountingV.A.G 1359/2 in conjunction with engine and gearbox jackV.A.G 1383 A).
3. Screw two M8×30 hexagon bolts (A) into flange.
4. After removing, check shims for damage.
5. Heat bearing to approx. 100° C, fit in position and press home.

6. ⚠ Wear protective gloves! — Insert previously determined shim "„S"3“ for pinion shaft . [Note: Inscription "„Oben“" (up) on thrust pad3253/4 faces nut of fitting tool.]
7. Lubricate outer race and press in with press toolVW 408 A and thrust plate30 - 205.
8. Insert pinion shaft with new spacer sleeve.
9. ⚠ Wear protective gloves! — Heat small tapered roller bearing inner race to approx. 100° C and fit onto pinion shaft.
10. Press up pinion shaft and insert bearing with drift sleeve40 - 21 to stop.
11. Insert O-ring with gear oil.
12. Lightly oil outer circumference of oil seal.
13. Fill space between sealing lip and dust lip with sealing greaseG 052 128 A1.
14. Drive in seal to stop with drift3026.
15. Drive propshaft flange onto pinion shaft far enough that securing nut can be fitted.
16. Screw in two M8×30 hexagon bolts(A).
17. The rear final drive must be supported when nut is tightened (e.g. with universal gearbox mountingV.A.G 1359/2 in conjunction with engine and gearbox jackV.A.G 1383 A). [Note: Increase torque setting slowly and check friction torque at regular intervals. If the prescribed friction torque is exceeded, the spacer sleeve must be renewed and the adjustment repeated. A spacer sleeve which has been compressed too much cannot be reused.] [Note: Use 3/4" to 1/2" reducer if necessary.]
18. Adjust to the following frictional torque:
19. Peen pinion shaft nut with a punch. [Note: The radial run-out at propshaft flange must be measured and marked .]

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