Replacing needle bearing (polygon bearing) for output shaft/drive flange on right-hand side — VW

The replacing needle bearing (polygon bearing) for output shaft/drive flange on right-hand side for the New Beetle RSi is fundamentally similar to the Audi TT 1999 ä; 5/6-speed manual gearbox 02MFour-wheel drive/final drives with code letters EUK.

The following description deals with the Audi TT. Therefore differences must be considered, if necessary.

Special tools and workshop equipment required

VW 401 Thrust plate
VW 402 Thrust plate
VW 407 Press tool
VW 412 Press tool
3253/5 Assembly device
T10047 Assembly device

3287 A Ball joint puller
V.A.G 1669
or 6 mm socket attachment, at least 190 mm long (commercially available)
Special tool T10037
Container

Removing

Unscrew nut for connecting link from right-hand anti-roll bar.

Unscrew upper nut from right-hand ball joint.

Position pressing-out tool as illustrated and press out ball joint.

Note:

Leave nut several threads on the ball joint to protect thread.

Turn steering wheel to the left.

Unbolt the heat shield for the drive shaft, right from angle drive.
Unscrew right-hand drive shaft from gearbox and tie up:

=> Running gear, Front and four-wheel drive; Repair group 40; Drive shafts; Removing and installing drive shaft
Running gear, Front and four-wheel drive
Drive shafts
Removing and installing drive shaft

Place container underneath engine.

Unscrew oil return line for the turbocharger from engine oil sump and cylinder block -arrows 2 and 3-.
Place container under the gearbox.
Remove bolt for right-hand flange shaft -arrow 1- with V.A.G 1669.

Pull out gear flange for flange shaft with special tool T10037 .

Now install assembly device T10047 as follows:

Align both parts of the device so that the markings "B" point towards each other.
The shoulders (arrows) must be underneath the bearing.
Now bolt both halves together until limit stop.

Lever off circlip -A- for the bearing.
In order not to damage the running surface of the bearing on the shaft it must be turned during the press procedure (arrow).

Installing

Assemble the assembly tool T10047
=>Fig. A39-0298 on Page
39-5
.

In order not to damage the running surface of the clutch on the shaft the shaft must be turned during the pressing procedure (arrow).
Secure bearing with new circlip.

Carefully drive in gear flange for flange shaft, turn whilst doing so.
Attach gear flange for flange shaft with taper head bolt.
Install oil return line from turbocharger with new seal.
Bolt on drive shaft.

=> Running gear, Front and four-wheel drive; Repair group 40; Drive shafts; Removing and installing drive shaft
Running gear, Front and four-wheel drive
Drive shafts
Removing and installing drive shaft

Check gear oil in gearbox with angle drive

=> 5/6-speed manual gearbox 02M, Four-wheel drive/gearbox; Repair group 34; Checking gear oil in manual gearbox with angle drive
5/6-speed manual gearbox 02M, Four-wheel drive/gearbox
Checking gear oil in manual gearbox with angle drive

Top up engine oil:

=> 4-Cylinder engine (5 valve turbo), Mechanical parts; Repair group 17; Removing and installing parts of lubricating system; Engine oil
4-Cylinder engine (5 valve turbo), Mechanical parts
Removing and installing parts of lubricating system
Engine oil

Tightening torques

Component · Nm
Drive flange to gearbox (tapered bolt) · / 25
Drive shaft to flange shaft · 70
Drive shaft heat shield · 25
Oil return pipe to sump · 10
Oil return line to cylinder block · 10