AUDI A8 1997 D2 / 1.G 01V Transmission Drive Pinion Assembly Workshop Manual

39-152


Drive pinion, removing,
installing, disassembling and
assembling Special tools and equipment

VW401 thrust plate
VW402 thrust plate
VW407 punch
VW408A punch
VW412 punch
VW457 support channels
Pa
ge 1 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-153



VW460/2 drift
VW 519 sleeve
VW540 holding fixture
30-205 thrust pad
2003/3 seal installer
2052/2 assembly tool for drive pinion
Pa
ge 2 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-154



3005 thrust pad
3062 thrust pad
3138 drift
3253 wheel bearing assembly set with 3253/3
and 3253/4
3304 retainer
Engine/transmission jack VAG1383A
engine/gearbox jack
Pa
ge 3 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-155


Item 1: Kukko21/7 extractorItem 2: Kukko 22/2 supportItem 3: Kukko 17/2 separatorTorque gauge 0 - 600 Ncm32 wrench insert hex socket
Pa
ge 4 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-156

Notes:

General repair notes page 00
-27
.

Disconnect torque tube from rear final drive with
the final drive installed page 39
-96
.

Disconnect torque tube from rear final drive with
the final drive removed page 39
-126
.

Replace both tapered roller bearings together. If
possible, use same manufacturer!
Do not grease new tapered roller bearings
additionally for friction torque measurement.
The bearings are already greased with a
special oil from the factory.
Removing differential page 39
-128
.

Adjustments are required when replacing
components marked with
1) Adjustment
overview page 39
-170
.
Pa
ge 5 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-157


1 -
Nut
Always replaceUnbolt Fig. 1
and Fig. 2
Unbolt Fig. 11Measuring friction torque Fig. 12Secure Fig. 13
2 -
Small tapered roller bearing inner race
1)
Press out drive pinion Fig. 3Pressing on Fig. 10
3 -
Small tapered roller bearing outer race
1)
Pulling out Fig. 4Pressing in Fig. 9
4 -
Spacer sleeve
1)
Always replace
5 -
Final drive housing
1)
Pa
ge 6 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-158


6 -
Shim "S3"
Note thicknessAdjustment overview page 39
-170
7 -
Large tapered roller bearing outer race
1)
Driving out Fig. 5Pulling in Fig. 8
8 -
Large tapered roller bearing inner race
1)
Pressing off Fig. 6Pressing on Fig. 7
9 -
Drive pinion
1)
Matched to ring gear, always replace
together as a set
Pa
ge 7 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-159


Fig. 1 Tools for removing and installing drive pinion nut
A - 32 mm wrench socket

Fig. 2 Removing drive pinion nut
- Install 3304 retainer using two hex bolts M8 x 30.
- When nut is removed, final drive must be supported (e.g. using
VAG1359/2 universal mount together with VAG1383A transmission
hoist).
Pa
ge 8 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-160


Fig. 3 Pressing out drive pinion from small tapered roller bearing
inner race

Fig. 4 Pulling out small tapered roller bearing outer race
A - Support e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7 extractor
Pa
ge 9 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14

39-161


Fig. 5 Driving out large tapered roller bearing outer race
- Check adjustment shims for damage after removing.

Fig. 6 Pressing off large tapered roller bearing inner race from
drive pinion
A - Separating device 22-115 mm, e.g. Kukko 17/2 separating tool
Pa
ge 10 of 14 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
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.AT01.39.14