Rear Final Drive, Disassembling and Assembling

Prepare the following special tools and test equipment:
^ VW401 thrust plate
^ VW402 thrust plate
^ VW407 punch
^ VW412 punch
^ VW295 needle bearing drift
^ VW408A punch
^ VW442 thrust pad
^ Sleeve 40-21
^ Thrust piece 40105
^ Thrust plate 2050
^ Drift 3138
^ Kukko 44/2 two arm puller





^ VAG1582 taper roller bearing puller





^ VAG1582/6 attachment to VAG1582

Notes:
^ General repair instructions.
^ Secure final drive on a repair stand.
^ Always replace both taper roller bearings together as a set.
^ Adjustments are required when replacing components marked 1), adjustment overview.





1. Cover for final drive 1)
2. O-ring
^ Replace
^ Lubricate with oil when installing
3. Final drive housing 1)
4. Shim "S1"
^ Note thickness
^ Adjustment overview
5. Outer race for small taper roller bearing 1)
^ Knocking out see Fig. 1
^ Pressing in see Fig. 2
6. Inner race for small taper roller bearing 1)
^ Pulling out see Fig. 3
^ Pressing in see Fig. 4
7. Bolt, 60 Nm turn 45 further
^ Replace
^ Allocation
^ Lightly tighten bolts then tighten diagonally to correct torque
8. Differential housing 1)
9. Ring gear 1)
^ Paired with drive pinion (final drive set)
^ Select correct version according to code letters
^ Drive off housing with a punch see Fig. 9
^ Installing on differential housing see Fig. 10
10. Spring pin
^ For securing planet pinion axis shaft
^ Drive in flush
11. Inner race for large taper roller bearing 1)
^ Pulling off see Fig. 5
^ Pressing on see Fig. 6
12. Outer race for large taper roller bearing 1)
^ Driving out see Fig. 7
^ Pressing in see Fig. 8
13. Shim "S2"
^ Note thickness
^ Adjustment overview
14. Threaded piece
15. Sun wheel
^ Installing see Fig. 11
^ Adjusting see Fig. 12
16. Planet pinion
^ Installing see Fig. 11
17. Planet pinion axis shaft
^ Knock out with drift
18. Shim
^ Redetermining thickness see Fig. 12
19. Thrust washer
^ Check for cracks





Fig. 1 Knocking outer race of small taper roller bearing out of housing
- After removing check shims for damage.





Fig. 2 Pressing outer race of small taper roller bearing into transmission housing (press to stop)





Fig. 3 Pulling off inner race for small taper roller bearing
A - Two arm puller, e.g. Kukko 44/2





Fig. 4 Pressing on inner race for small taper roller bearing

WARNING: Wear protective gloves.

- Heat bearing to approx. 100°C, fit in position and press home.





Fig. 5 Pulling off inner race for large taper roller bearing
- Before fitting the extractor position press piece 40-105 on differential housing.





Fig. 6 Pressing on inner race for large taper roller bearing

WARNING: Wear protective gloves.

- Heat bearing to approx. 100°C, fit in position and press home.





Fig. 7 Driving outer race for large taper roller bearing out of cover
- After removing check shims for damage.





Fig. 8 Pressing outer race for large taper roller bearing into cover





Fig. 9 Driving ring gear off housing





Fig. 10 Installing ring gear

WARNING: Wear protective gloves.

- Use centering pins -A- (local manufacture) as a guide.
- Heat ring gear to approx. 100°C and install.





Fig. 11 Installing sun wheels and planet pinions
- If the sun wheels have been replaced, measure and select new shims see Fig. 12
- Insert sun wheels with the measured shims.
- Install planet pinions at 180 from their final position, and rotate into place-arrow-.
- Fit and align thrust washers.
- Insert threaded pieces.
- Drive planet pinion axis shaft into final position and secure.





Fig. 12 Adjusting sun wheels and planet pinions
- Insert sun wheels with thinnest shims (0.5 mm).
- Insert planet pinions with thrust washers at 180° from their final position.

Note: Do not now interchange planet pinions and thrust washers.

- Drive in planet pinion axis shaft.
- Press planet pinions outward.
- Press sun wheels in direction indicated (arrows), and check the amount of play.
- Determine the thickest shims for the sun wheels (on each side) which can still just be inserted.
- Select shims of equal thickness.
- Identify shims according to the table.





The following shims are available:





Note: The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the sun wheels and planet pinions -arrow-.