Servicing shaft bevel gear bearings — VW

Special tools, testers and auxiliary items

Press plate VW 402
Press tool VW 408 a
Press tool VW 409
Press tool VW 412
Tube VW 415 a
Extractor lever VW 681
Press tool 30-11
Extension 30-23
Sleeve 30-100
Press tool 40-20
Tube 2040
Press tool 2050

Press tool 3124
Drift 3138
Socket 3156
Drift sleeve 3158
Torque wrench V.A.G 1332
Puller V.A.G 1582
Grip piece V.A.G 1582/1

Rear axle housing has been removed from bevel gear housing => Page
39-126
.

Take bevel gear with input shaft out of bevel gear housing.
Pull seal out with VW 681.
Remove hexagon nut for shaft bevel gear.

A - Ring spanner SW41
B - Torque wrench - turn clockwise to remove

Pressing small taper roller bearing inner race off shaft bevel gear.

Notes:

Lower edge of bevel gear housing is located in pressure plate VW 402 rear cut out.
After pressing out check housing joint flange for damage.

Drive small taper roller bearing outer race out of bevel gear housing.

Drive large taper roller bearing outer ring out of bevel gear housing.

A - Internal puller 56 ... 70 mm, e.g. Kukko 21/8
Previously:
Push driver 3138 through large taper roller bearing outer race hole in the direction of seal seat, then expand and drive outer race out against foot of internal puller -A-.

Remove shim S3.

Pulling large taper roller bearing inner race off shaft bevel gear.

For vehicles with 6 cylinder injection engine:

First place press piece 30-11 on shaft bevel gear.

Press large taper roller bearing inner race on shaft bevel gear with tube VW 415 a.
Pressing shaft bevel gear large taper roller bearing outer race in bevel gear housing.

First insert shim S3.

Pressing shaft bevel gear small taper roller bearing outer race in bevel gear housing.

Notes:

Step of tube VW 415 a to pressure plate VW 402.
Place bearing outer race on tube VW 415a.
Do not cant when pressing in.

Fit shaft bevel gear in bevel gear housing.
Place on a new distance sleeve.
Lightly press small taper roller bearing inner race onto shaft bevel gear.

The distance sleeve must not be pressed together whilst pressing on.

Fit hexagon nut to shaft bevel gear.
Tighten hexagon nut to 120 Nm, then measure friction torque => Page
39-136
, if necessary increase tightening torque further until the correct friction torque is set.

A - Ring spanner 41 mm AF
B - Torque wrench - to screw on turn anti-clockwise

Note:

Increase tightening torque 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.

Set friction torque as follows:

new bearings · used bearings 1)
200 ... 250 Ncm · 30 ... 50 Ncm

1)
run at least 50 km (30 miles)

Measure friction torque.

With torque gauge, 0 ... 600 Ncm, commercially available

Drive new seal in onto stop with sleeve 3158. When doing this do not cant seal.