Differential Removing and Installing

Notes:
- Refer to, Manual Transmission/Transaxle, Service and Repair.
- Refer to Rear Final Drive To Repair Stand, Mounting.
- Adjustments are required when replacing components marked with 1), Refer to Differential Assembly, Adjustments for List of adjustments.

1. Breather sleeve
- With rubber valve
- Installation position refer to Fig. 3
2. Final drive housing 1)
- With pinion shaft
- Removing and installing drive pinion, Refer to Pinion Shaft, Removing and Installing and Servicing.
3. Large tapered roller bearing outer race 1)
4. Shim S1
5. Final drive cover 1)
- Always replace O-ring
- With 0-ring
- Lubricate O-ring with oil when installing
6. Torx bolt
- 25 Nm (18 ft. lbs.)
7. Right seal
- Replacing, Refer to Differential Assembly, Seals and Gaskets, Differential, Service and Repair.
8. Socket head bolt
- 25 Nm (18 ft. lbs.)
9. Drive flange, right
- Removing and installing refer to Fig. 1
10. Oil filler plug
- 35 Nm (26 ft. lbs.)
11. Differential with ring gear 1)
12. Oil drain plug
- 35 Nm (26 ft. lbs.)
13. Bushing
- Holds magnet in position
- Drive in onto stop
14. Magnet
15. Small tapered roller bearing outer race 1)
- Removing, See Fig. 1, Refer to Differential, disassembling and Assembling.
- Installing, See Fig. 2, Refer to Differential, disassembling and Assembling.
16. Shim S2
17. Left seal
- Replacing, Refer to Differential Assembly, Seals and Gaskets, Differential, Service and Repair.
18. Drive flange, left
- Removing and installing refer to Fig. 1
19. Socket head bolt
- 25 Nm (18 ft. lbs.)
20. Cover
- Installing refer to Fig. 2





Fig. 1 Removing and installing drive flange
- To loosen mounting bolt, screw in 2 bolts in drive flange and counter-hold using pry bar.
- Pull out drive flange using screwed in bolts.





Fig. 2. Press in cover onto stop





Fig. 3. Position of breather sleeve
The breather sleeve should project 13 mm (0.512 inch) dimension -a- out of final drive housing after pressing in.
The slot in the rubber valve should be in line with the direction of travel.

Removing
- Final drive removed

Special tools and equipment
VAG1306 drip tray
Secure complete final drive to repair stand using VW540 bracket Mounting.
Place drip tray under final drive and drain gear oil.





- Remove left and right drive flanges:
- To loosen mounting bolt, screw two bolts into drive flange and counter-hold with pry bar.
- Mark drive flanges (left and right).
- Pull out drive flange using screwed in bolts.
- Remove mounting bolts from final drive cover.
- Remove final drive cover from final drive housing and remove differential.

Installing
Install in reverse order of removal.
- Install differential.
- Replace O-ring for final drive cover and lubricate before installing.
- Install final drive cover on final drive housing and tighten in diagonal sequence to 25 Nm (18 ft. lbs.).
- Replace seals for drive flange, Refer to Seals and Gaskets, Differential, Service and Repair.
- Fill space between sealing lip and dust lip with gear oil





- Install drive flanges and tighten 25 Nm (18 ft. lbs.).
- Top off gear oil in final drive and check oil level.