Disassembling and Assembling

Notes:
- General Repair notes.
- Replace both differential tapered roller bearings together if possible use bearings from the same manufacturer





1- Cover
2- O-ring
- Always replace
3- Final drive housing
4- Shim S1
- Note thickness
- Adjustment overview
5- Small tapered roller bearing outer race
- Driving out refer to Fig. 10
- Driving in refer to Fig. 11
6- Small tapered roller bearing inner race
- Removing refer to Fig. 2
- Pressing on refer to Fig 4
7- Bolt
- Always replace
- Use only original Part No.
- Tighten evenly, then tighten in cross wise pattern to 60 Nm plus a further 45° (1/8 turn)
8- Differential gear housing
9- Ring gear
- Paired with pinion (pinion set)
- When replacing pinion set pinion and ring gear must be adjusted
- Drive off with mandrel refer to Fig. 5
- Installing refer to Fig. 6
- Warm ring gear to 100°C (212°F) for assembly
10- Spring pin
- drive in flush
11- Large tapered roller bearing inner race
- Removing refer to Fig. 1
- Pressing on refer to Fig. 3
12- Large tapered roller bearing outer race
- Driving out refer to Fig. 12
- Pressing in refer to Fig. 13
13- Shim S2
- Note thickness
- Adjustment overview
14- Threaded washer
15- Differential bevel gear, large
- Adjustment refer to Fig. 8 and Fig. 9
16- Differential bevel gear, small
- Installing refer to Fig. 7
17- Shaft for differential gears
- Drive out with mandrel
- Drive in carefully, so that thrust washers are not damaged
- Secure with sleeve.
18- Adjustment shim Redetermine thickness refer to Fig. 8 and Fig. 9
19- Thrust washer
- Check for cracks and breaks

Fig. 1 Large tapered roller bearing inner race, removing





- Before setting up removal device, position pressure piece 40-105 on differential gear housing.

Fig. 2 Small tapered roller bearing inner race, removing from housing





A= Two arm extractor (commercial), e.g. Kukko 44/2

Fig-3 Large tapered roller bearing inner race, installing





- Heat bearing to 100°C (212°F), position and press on.

Fig. 4 Small tapered roller bearing inner race, installing





- Heat bearing to 100°C (212°F), position and press on





Fig. 5 Ring gear, removing from housing

Fig. 6 Ring gear, positioning





- Heat ring gear to 100°C (212°F).
- Use centering pin -A- (fabricated) to guide.

Fig. 7 Differential gear, installing





- Install large gears with correct shims (Figs. 8 and 9).
- Install small gears offset by 180° (bond thrust washer with small amount of grease) and slide in.
- Align thrust washers.
- Install threaded washer.
- Drive in shaft and secure.

Fig. 8 Differential gear, adjusting





- Install large gear with thinnest shim (0.5 mm).
- Install small gears with thrust washers and press in shaft.

CAUTION!
Do not exchange differential gear and thrust washer positions.

- Press small gear outward and check play of large gear by hand -arrows,
- Adjust play by inserting shim.
- Max. play = 0.1 mm

Notes:
If no play can be felt, the adjustment is still correct if the differential gears can be turned (Fig. 9).





Fig. 9 Differential gear, turning





Fig.10 Small tapered roller bearing outer race, driving out of final drive housing

Fig. 11 Small tapered roller bearing outer race, driving into final drive housing





- Position outer race with VW 295 and tap lightly with hammer.
- Drive in as far as possible per illustration.





Fig. 12 Large tapered roller bearing outer race, driving out of cover





Fig. 13 Large tapered roller bearing outer race, pressing into cover