Differential, Disassembling and Assembling
Differential, disassembling and assembling
Special tools, testers and auxiliary items
^ Drift VW 295
^ Press plate VW 401
^ Press plate VW 402
^ Press tool VW 407
^ Press tool VW 408 A
^ Press tool VW 412
^ Press tool VW 442
^ Press tool 40-21
^ Thrust plate 40-105
^ Thrust pad 2050
^ Drift 3138
^ Tapered roller bearing puller V.A.G 1582 and V.A.G 1582/6
^ Two-arm puller Kukko 44/2
Note:
^ General repair instructions, Refer to Manual Transaxle, Service and Repair.
^ Replace both tapered roller bearings of the differential together. Use same make if possible.
^ Adjustments are required when replacing components marked 1), Refer to Differential Assembly, Adjustments, Adjustment overview
1. Cover for final drive 1)
2. O-ring
^ Always replace
^ Insert with oil
3. Final drive housing 1)
4. Shim "S2"
^ Note thickness
^ Adjustment overview, Refer to Differential Assembly, adjustments
5. Outer race for small tapered roller bearing 1)
^ Knocking out, Refer to Fig. 1
^ Pressing In, Refer to Fig. 2
6. Inner race for small tapered roller bearing 1)
^ Pulling out, Refer to Fig. 3
^ Pressing in, Refer to Fig. 4
7. Bolt, 60 Nm + turn 45° further
^ Always replace
^ Allocation
Refer to Parts Supplier
^ 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
Refer to Parts Supplier
^ Drive off housing with a punch, Refer to Fig. 9
^ Installing on differential housing, Refer to Fig. 10
10. Spring pin
^ For securing planet pinion axis shaft
^ Drive in flush
11. Inner race for large tapered roller bearing 1)
^ Pulling off, Refer to Fig. 5
^ Pressing on, Refer to Fig. 6
12. Outer race for large tapered roller bearing 1)
^ Driving out, Refer to Fig. 7
^ Pressing in, Refer to Fig. 8
13. Shim "S1"
^ Note thickness
^ Adjustment overview, Refer to Differential Assembly, adjustments
14. Threaded piece
15. Sun wheel
^ Installing, Refer to Fig. 11
^ Adjusting, Refer to Fig. 12
16. Planet.pinion
^ Installing, Refer to Fig. 11
17. Planet pinion axis shaft
^ Knock out with drift
^ Drive in carefully so that the thrust washers are not damaged
^ Secure with spring pin- 10
18. Shim
^ Redetermining thickness, Refer to Fig. 12
19. Thrust washer
^ Check for cracks
Fig. 1 Knocking outer race of small tapered roller bearing out of housing
- After removing check shims for damage.
Fig. 2 Pressing outer race of small tapered roller bearing into housing (press against stop)
- Position outer race using VW 295 and light even blows with a hammer.
- Drive in onto stop as shown in illustration.
Fig. 3 Pulling off inner race for small tapered roller bearing
A - Two arm puller, e.g. Kukko 44/2
Fig. 4 Pressing on inner race for small tapered roller bearing
CAUTION: Wear protective gloves.
- Heat bearing to approximately 100°C, fit in position and press home.
Fig. 5 Pulling off inner race for large tapered roller bearing
- Before fitting extractor position press piece 40-105 on differential housing.
Fig. 6 Pressing on inner race for large tapered roller bearing
CAUTION: Wear protective gloves.
- Heat bearing to approximately 100°C, fit in position and press home.
Fig. 7 Driving outer race for large tapered roller bearing out of cover
- After removing check shims for damage.
Fig. 8 Pressing outer race for large tapered roller bearing into cover
Fig. 9 Driving ring gear off housing
Fig. 10 Installing ring gear
CAUTION: Wear protective gloves.
- When fitting ring gear guide centralizing pins -A- (local manufacture).
- Heat ring gear to approximately 100°C and install.
Fig. 11 Installing sun wheels and planet pinions
- If sun wheels have been replaced, measure and select new shims , Refer to Fig. 12.
- Insert sun wheels with measured shims.
- Install planet pinions spaced 180° apart, and rotate into position (arrow).
- Fit and align thrust washers.
- Insert threaded pieces.
- Drive planet pinion shaft into final position and secure.
Fig. 12 Adjusting differential bevel gears
- Insert sun wheels with thinnest shims (0.5 mm).
- Insert planet pinions with thrust washers spaced 180° apart.
Note: Do not now interchange bevel gears 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 thickest shims for sun wheels (on each side) which can still just be inserted.
The same thickness of shim should be used on both sides.
- Identify shims according to table.
Refer to Parts Supplier
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 differential bevel gears (arrow).