Differential, Removing and Installing

Differential, removing and installing

Note:
^ General repair instructions, Refer to Manual Transaxle, Service and Repair.
^ Secure final drive on a repair stand, Refer to Rear Final Drive, Securing to Repair Stand
^ Adjustments are required when replacing components marked 1) , Refer to Differential Assembly, adjustments, Adjustment overview

1. Breather sleeve
^ With rubber valve
^ Installation position, Refer to Fig. 3
2. Final drive housing 1)
^ With drive pinion
^ Removing and installing drive pinion, Refer to Drive Pinion, Removing, Installing, Disassembling and Assembling
3. Outer race for large tapered roller bearing 1)
^ Driving out, Refer to Differential, Disassembling and Assembling, See Fig. 7
^ Driving in, Refer to Differential, Disassembling and Assembling, See Fig. 8
4. Shim "S1"
^ Note thickness
^ Adjustment overview, Refer to Differential Assembly, adjustments
5. Cover for final drive 1)
^ With seal
^ Replace O-ring
^ Lubricate O-ring with oil when installing
6. Torx bolt, 25 Nm
7. Seal, right
^ Replacing, Refer to Seals and Gaskets, Differential, Service and Repair
8. Hex socket head bolt, 25 Nm
9. Drive flange, right
^ Removing and installing, Refer to Fig. 1
10. Oil filler plug, 35 Nm
11. Differential with ring gear 1)
^ Disassembling and assembling, Refer to Differential, Disassembling and Assembling
12. Oil drain plug, 35 Nm
13. Bushing
^ Holds magnet in position
^ Knock in onto stop
14. Magnet
15. Outer race for small tapered roller bearing 1)
^ Knocking out, Refer to Differential, Disassembling and Assembling, See Fig. 1
^ Pressing in, Refer to Differential, Disassembling and Assembling, See Fig. 2
16. Shim "S2"
^ Note thickness
^ Adjustment overview, Refer to Differential Assembly, adjustments
17. Seal, left
^ Replacing, Refer to Seals and Gaskets, Differential, Service and Repair
18. Drive flange, left
^ Removing and installing, Refer to Fig. 1
19. Hex socket head bolt, 25 Nm
20. Cover
^ Installing, Refer to Fig. 2





Fig. 1 Removing and installing drive flange
- To loosen securing bolt, screw two bolts into drive flange and counter-hold with a lever.
- Pull out drive flange using bolts already screwed in.





Fig. 2 Pressing cover onto stop





Fig. 3 Position of breather sleeve
The breather sleeve should project 13 mm (distance "a") out of the housing after pressing in.
The slot in the rubber valve should be in line with the direction of travel.

Removing and installing differential
Rear final drive removed

Special tools, testers and auxiliary items
^ Drip tray V.A.G 1306

Removing
- Secure complete rear final drive on a repair stand, Refer to Rear Final Drive, Securing to Repair Stand
- Place drip tray V.A.G 1306 underneath and drain oil.
- Fill space between sealing lip and dust lip with sealing grease G52 128 A1.





- Remove left and right-hand drive flanges.
- To loosen securing bolt, screw two bolts into drive flange and counter-hold with a lever.
- Mark drive flanges (for left and right sides).
- Pull out drive flange using the bolts already screwed in.
- Unscrew securing bolts from cover for final drive.
- Take cover for final drive off axle housing and remove differential.

Installing
Installation is carried out in the reverse order, when doing this note the following:
- Insert differential.
- Replace O-ring for cover for final drive and oil when installing.
- Fit cover for final drive on final drive housing and tighten in diagonal sequence to 25 Nm.
- Replace drive flange oil seals, Refer to Seals and Gaskets, Differential, Service and Repair
- Fill space between sealing and dust lips with sealing grease G52 128 A1.





- Install drive flanges and tighten to 25 Nm.
- Top-up gear oil in rear final drive and check oil level.