AUDI A6 1996 C5 / 2.G 01E Transmission Final Drive Pinion Assembly Workshop Manual

39-134


Drive pinion, removing,
installing, disassembling and
assembling

Special tools, testers and auxiliary items

Press plate VW 401
Press plate VW 402
Press tool VW 407
Press tool VW 408 A
Press tool VW 412
Support rails VW 457
Mandrel VW 460/2
Tube VW 519
Engine and transmission support VW 540
Thrust plate 30-205
Pa
ge 1 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
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Installing ring 2003/3
Pinion assembly appliance 2052/2
Thrust plate 3005
Pa
ge 2 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
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39-135

Thrust pad 3062
Drift 3138
Fitting appliance 3253 with 3253/3 and
3253/4
Retainer 3304
Engine/transmission jack V.A.G 1383 A
Universal support V.A.G 1359/2
Separating tool Kukko 17/2
Two-arm puller Kukko 21/7
Counter-support Kukko 22/2
Torque gauge 0-600 Ncm
Socket attachment (long), 32 mm A/F
Pa
ge 3 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
11/19/2002 htt
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39-136

Note:

General repair instructions Page 00
-11
.

Removing drive flange housing from rear final
drive with final drive installed Page 39
-82
.

Removing drive flange housing from rear final
drive with final drive removed Page 39
-111
.

Replace both tapered roller bearings together.
Use same make if possible.
Do not additionally oil new tapered roller
bearings for friction torque measurement. The
bearings have already been treated with a
special oil by the manufacturer.
Removing differential Page 39
-112
.

Adjustments are required when replacing
components marked with a 1) Page 39
-150
,
Adjustment overview
Pa
ge 4 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
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39-137


1 -
Nut
Always replaceRemoving Fig. 1
and Fig. 2
Installing Fig. 11Measuring friction torque Fig. 12Securing Fig. 13
2 -
Inner race for small tapered roller bearing
1) Pressing out drive pinion Fig. 3Installing Fig. 10
3 -
Outer race for small tapered roller bearing
1) Pulling out Fig. 4Pressing in Fig. 9
4 -
Spacer sleeve
1)
Always replace
5 -
Final drive housing
1)
Pa
ge 5 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
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39-138


6 -
Shim "S3"
Note thicknessAdjustment overview Page 39
-150
7 -
Outer race for large tapered roller bearing
1) Driving out Fig. 5Pulling in Fig. 8
8 -
Inner race for large tapered roller bearing
1) Pulling off Fig. 6Pressing on Fig. 7
9 -
Drive pinion
1)
Is mated with ring gear, always replace
together as a set
Pa
ge 6 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
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39-139


Fig. 1 Tools for loosening and tightening drive pinion nut
A - Socket (32 mm)

Fig. 2 Removing nut for drive pinion
- Secure retainer 3304 with two M8 x 30 hex bolts.
- Support final drive when loosening nut (e.g. using universal support
V.A.G 1359/2 in combination with transmission jack V.A.G 1383 A).
Pa
ge 7 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
11/19/2002 htt
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39-140


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

Fig. 4 Pulling out outer race for small tapered roller bearing
A - Counter support e.g. Kukko 22/2
B - Internal puller 46-58 mm, e.g. Kukko 21/7
Pa
ge 8 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
11/19/2002 htt
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e=re
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39-141


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

Fig. 6 Pressing inner race for large tapered roller bearing off
drive pinion
A - Separating device 22-115 mm, e.g. Kukko 17/2
Pa
ge 9 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
11/19/2002 htt
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39-142


CAUTION!
Wear protective gloves. Fig. 7 Pressing inner race for large tapered roller bearing onto
drive pinion
-
Heat bearing to approx. 100 C, fit in position and press home.

Note:
Inscription "Oben" faces the nut of the puller with thrust washer 3253/4. Fig. 8 Pulling in outer race for large tapered roller bearing
- Insert predetermined shim "S3" for drive pinion Page 39
-154
.
Pa
ge 10 of 13 Drive
pinion, removin
g, installin
g, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.39.18