Differential, Removing and Installing

Notes:
- The differential can be removed and installed without disassembling the shift mechanism, input shaft, pinion and cover (not shown).
- Disassembly of these parts is necessary for adjusting the differential.

1. Drive flange
- Remove to install differential: described below
- Drive in with VW 295
2. Circlip
- Always replace
- Removing and installing: described below
3. Transmission housing
4. Shim -S2-
- Note thickness
- Adjustment table: Ring and Pinion Gear Set, List Of Adjustments. Adjustments
5. Outer race for small tapered roller bearing
- Pulling out: described below
- Driving in: described below
6. Inner race for small tapered roller bearing
- Pulling off: described below
- Press on with installing sleeve, special tool 40-21
7. Differential
- Refer to "Disassembling and Assembling"
8. Inner race for tapered roller bearing
- Pulling off: described below
- Press on with installing sleeve, special tool 40-21
9. Outer race for large tapered roller bearing
- Pulling off: described below
- Drive in with drift VW 295 and VW 511
10. Shim -S1-
- Note thickness
- Adjustment table: Ring and Pinion Gear Set, List Of Adjustments. Adjustments
11. Final drive cover
- Seal with AMV 188 200
12. Torx bolt
- 25 Nm (18 ft lb)
13. Oil seal
- Pull out with VW 681
- Driving in: described below
14. Speedometer drive gear for electronic speedometer
- Can be replaced with transmission installed
- Installation position: Service and Repair
15. Oil seal
- Pull out with VW 681
- Driving in: described below





Removing Drive Flange
- Place chisel or spacer -A- behind drive flange.
- Pull drive flange shaft out of differential gears by turning bolt -B-.

Note: The procedure for removing the drive flange shafts on right and left sides is identical.






Replacing Drive Flange Shaft Circlip
- Clamp drive flange shaft into vise using protective jaws.
- Press old circlip out of groove in drive flange shaft using new circlip -A-.






Removing Outer Race Of Small Tapered Roller Bearing
- Remove outer race using puller and brace -A-, e.g. Kukko 21/7 (46-56 mm) and Kukko 22/2
- Outer race can also be removed using drift 3138.






Driving In Outer Race Of Small Tapered Roller Bearing






Pulling Off Inner Race Of Small Tapered Roller Bearing
- A = Two-arm Puller, e.g. Kukko 44/2






Pulling Off Inner Race Of Large Tapered Roller Bearing
- A = Two-arm Puller, e.g. Kukko 204/2






Pulling Off Outer Race Of Large Tapered Roller Bearing
- Remove outer race using puller and brace -A-, e.g. Kukko 2117 (46-56 mm) and Kukko 22/2.
- Outer race can also be removed using drift 3138.






Driving In Oil Seal For Drive Flange Into Final Drive Cover
- Drive in until 5.5 mm (0.217 in.) below upper edge of cover.






Drive In Oil Seal For Drive Flange Into Transmission Housing
- Drive in seal until 5.5 mm (0.217 in.) below outer edge of housing.