AUDI A4 1996 B5 / 1.G 01A Transmission Pinion Shaft Remove And Install Workshop Manual

39-134


Pinion shaft, removing,
installing and servicing

Special tools and equipment

VW401 thrust plate
VW402 thrust plate
VW407 punch
VW408A punch
VW412 thrust disc
VW457 support channels
VW460/2 mandrel
VW519 sleeve
VW540 engine/transmission support
30-205 thrust pad

Pa
ge 1 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
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2003/3 seal installer
2052/2 assembly tool for pinion shaft
3005 thrust pad
Pa
ge 2 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
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3062 thrust pad
3138 drift
3253 wheel bearing assembly set with 3253/3
and 3253/4
3304 bracket
VAG1383A engine/transmission support
VAG1359/2 universal mount
Kukko 17/2 separating tool
Kukko 21/7 extractor
Kukko 22/2 support
Torque gauge 0-600 Ncm (0-53 in. lb)
32 mm socket
Pa
ge 3 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
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yp
e=re
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39-136

Notes:

Observe general repair instructions Page 00
-
14
.

With the final drive installed, remove the drive
flange housing from the rear final drive Page 39
-86
.

With the final drive removed, remove the drive
flange housing from the rear final drive Page 39
-119
.

Always replace both tapered roller bearings
together as a set. If possible, use same
manufacturer.
Do not oil new tapered roller bearings for the
friction torque measurement. The bearings are
already factory treated with a special oil.
Remove differential Page 39
-114
.

Adjustments are required when replacing
components marked with "1)" List of
adjustments, Page 39
-149
.
Pa
ge 4 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
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39-137


1 -
Pinion shaft nut
Always replaceRemoving Figs. 1
and 2
Installing Fig. 1Measuring friction torque Fig. 12Securing Fig. 13
2 -
Small tapered roller bearing inner race1)
Removing pinion shaft Fig. 3Installing Fig. 10
3 -
Small tapered roller bearing outer race1)
Removing Fig. 4Installing Fig. 9
4 -
Spacer sleeve1)
Always replace
5 -
Final drive housing1)
6 -
Shim S3 Note thicknessList of adjustments Page 39
-149
Pa
ge 5 of 13 Pinion shaft, removin
g, installin
g and servicin
g
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39-138


7 -
Large tapered roller bearing outer race1)
Removing Fig. 5Installing Fig. 8
8 -
Large tapered roller bearing inner race1)
Removing Fig. 6Installing Fig. 7
9 -
Pinion shaft1)
Is matched with ring gear, always replace
as a set
Pa
ge 6 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
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39-139


Fig. 1 Tool to loosen and tighten pinion shaft nut
A- 32 mm socket

Fig. 2 Removing pinion shaft nut
- Screw 3304 bracket on using two M8 x 30 hex-head bolts.
- Final drive must be supported when loosening nut (e.g. using
VAG1359/2 universal transmission attachment in combination with
VAG1383A transmission jack).
Pa
ge 7 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
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pair&id=AUDI.B5.TM02.39.16

39-140


Fig. 3 Removing pinion shaft from small tapered roller bearing
inner race

Fig. 4 Removing small tapered roller bearing outer race
A - Counter support e.g. Kukko 22/2
B - Internal puller 46-58 mm, e.g. Kukko 21/7
Pa
ge 8 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
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39-141


Fig. 5 Removing large tapered roller bearing outer race
- After removing, check shims for damage.

Fig. 6 Removing large tapered roller bearing inner race from
pinion shaft
A - Separating device 22-115 mm, e.g. Kukko 17/2
Pa
ge 9 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
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39-142


WARNING!
Wear protective gloves. Fig. 7 Installing large tapered roller bearing inner race onto
pinion shaft
-
Heat bearing to approx. 100 C (212 F), install and press down.

Note:
The marking "Oben" on 3253/4 thrust piece faces the nut of the puller. Fig. 8 Installing large tapered roller bearing inner race onto
pinion shaft
- First insert predetermined shim S3 for pinion shaft Page 39
-149
.
Pa
ge 10 of 13 Pinion shaft, removin
g, installin
g and servicin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.16