6-speed manual gearbox 01E, four-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 loosening the nut (e.g. with universal gearbox mountingV.A.G 1359/2 in conjunction with gearbox jackV.A.G 1383 A).
• Outer race must be put on with xxx driftVW 295 and thrust plate30-205.

📋 Procedure

1. The rear final drive must be supported when loosening the nut (e.g. with universal gearbox mountingV.A.G 1359/2 in conjunction with gearbox jackV.A.G 1383 A).
2. After removing, check shims for damage.
3. ⚠ Wear protective gloves! — Heat inner race to about 100° C before pressing on.
4. Insert previously determined shim "“S"3” for pinion shaft .
5. Outer race must be put on with xxx driftVW 295 and thrust plate30-205.

6. Insert pinion shaft with new spacer sleeve.
7. ⚠ Wear protective gloves! — Heat inner race to about 100 °C.
8. Press pinion shaft up and press inner race in fully to stop with press sleeve40-21.
9. Insert O-ring with gearbox oil.
10. Apply gear oil to circumference of seal.
11. Half-fill space between sealing lip and dust lip with greaseG 052 128 A1.
12. Drive new oil seal into rear axle housing to stop, being careful not to cant seal.
13. Drive propshaft flange onto pinion shaft far enough that securing nut can be fitted.
14. The rear final drive must be supported when tightening the nut (e.g. with universal gearbox mountingV.A.G 1359/2 in conjunction with 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.]
15. After securing nut, measure radial run-out at propshaft flange .

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