Disassembling and Assembling

Rear final drive, disassembling and assembling
Assembly overview





1. Final drive housing
2. Spacer sleeve
^ Always replace
3. Driveshaft flange
^ Removal and installation, Refer to Differential Pinion Flange.
4. Drive pinion
^ Matched to ring gear, always replace together as a set
^ Removal and installation, Refer to Differential Pinion Flange.
5. Cover for final drive
6. Differential
^ Removal and installation, Refer to Differential Assembly.
^ Disassembly and assembly, Refer to Differential Assembly.
7. Ring gear
^ Is matched to drive pinion (gear set)
^ Removal and installation, Refer to Ring Gear.

Differential, removing and installing

Note:
^ Adjustments are required when replacing components marked with 1).





1. Breather sleeve with rubber valve installed position, see Fig. 3
2. Final drive housing 1)
^ Removing and installing drive pinion
3. Double tapered roller bearing outer race 1)
4. Adjustment shim "S1"
^ Note thickness
^ List of adjustments, Refer to Adjustments.
5. Cover for final drive 1)
^ With O- ring
^ Replacing O-ring
^ Insert O- ring with oil
6. Torx bolt (25 Nm)
7. Right gasket
8. Socket- head bolt - 25 Nm
9. Right drive flange
^ Removing and installing see Fig. 1
10. Oil filler plug (35 Nm)
^ Check transmission fluid level in rear final drive.
11. Differential with ring gear 1)
^ disassembly and assembly, Refer to Differential, Disassembling and Assembling.
12. Oil drain plug (35 Nm)
13. Bushing
^ Holds the magnet in position
^ Press in up to stop
14. Magnet
15. Tapered roller bearing outer race 1)
^ Removal and installation, Refer to Differential, Disassembling and Assembling.
16. Shim "S2"
^ Note thickness
^ List of adjustments
17. Left gasket
18. Left drive flange
^ Removing and installing see Fig. 1
19. Socket- head bolt 25 Nm
20. Cover





Fig. 1 Drive flange, removal and installation





Fig. 2 Pressing in cover up to stop





Fig. 3 Installation position of breather sleeve

The breather sleeve must protrude 13 mm (measurement -a-) out of housing after pressing In.
The slot in the rubber valve is parallel to direction of travel.

Removing
^ Rear final drive removed

Special tools and equipment





^ VAG 1306 Drip tray
^ Secure entire final drive in VW540 holding fixture.
^ Place drip tray underneath.
^ Drain gear oil.





^ Remove left and right drive flanges.
^ To loosen securing bolt, thread in 2 bolts into drive flange and counter hold with tire iron.
^ Mark left and right drive flanges and pull out.
^ Remove mounting bolts for final drive cover.
^ Remove final drive cover from axle housing and remove differential.

Installing
Installation is the reverse of removal.
^ Install differential.
^ Replace O-ring for final drive cover and oil for installation.
^ Install final drive cover onto final drive housing and tighten in diagonal pattern to 25 Nm.
^ Lubricate area between sealing lip and dust lip with a thin layer of multipurpose grease.





^ Install drive flanges and tighten.
^ Top off transmission fluid in rear final drive and check oil level.

Differential, disassembling and assembling
Special tools and equipment





^ VW401 Thrust plate
^ VW402 Thrust plate
^ VW407 Punch
^ VW412 Punch
^ VW295 Needle bearing drift
^ VW408A Punch





^ VW442 Thrust pad
^ 40-21 Sleeve
^ 40-105 Thrust piece
^ 2050 Thrust plate
^ 3138 Drift
^ Kukko 44/2 Two- arm puller





^ VAG 1582 Taper roller bearing puller





^ VAG 1582/6





Note:
^ General repair notes.
^ Secure final drive in assembly fixture.
^ Replace both tapered roller bearings together.
^ Adjustments are required when replacing components marked with 1).
1. Cover for final drive 1)
2. O-ring
^ Replace
^ Insert with oil
3. Final drive housing 1)
4. Adjustment shim "S1"
^ Note thickness
5. Tapered roller bearing outer race 1)
^ Driving out see Fig. 1
^ Pressing in see Fig. 2
6. Tapered roller bearing Inner race 1)
^ Removing see Fig. 3
^ Pressing on Fig. 4
7. Bolt (60 Nm plus additional 45°)
^ Replace
^ Assignment, Refer to Parts Department.
^ Lightly tighten bolts then tighten diagonally to correct torque.
8. Differential housing 1)
9. Ring gear 1)
^ Is matched to drive pinion (gear set)
^ Application according to transmission code letters, Refer to Parts Department.
^ Drive from housing using mandrel see Fig. 9
^ Install onto differential housing see Fig. 10
10. Roll pin
^ For securing shaft for differential bevel gears
^ Drive in flush
11. Double tapered roller bearing inner race 1)
^ Removing see Fig. 5
^ Pressing on see Fig. 6
12. Double tapered roller bearing outer race 1)
^ Driving out see Fig. 7
^ Pressing in see Fig. 8
13. Shim "S2"
^ Note thickness
14. Threaded piece
15. Large differential bevel gear
^ Installing see Fig. 11
^ Adjusting see Fig. 12
16. Small differential bevel gear
^ Installing see Fig. 11
17. Shaft for differential bevel gears
^ Drive out using drift
18. Adjustment shim
^ Re- determining thickness see Fig. 12
19. Thrust washer
^ Check for cracks





Fig. 1 Driving small tapered roller bearing outer race out of housing
^ Check adjustment shims for damage after removing.





Fig. 2 Pressing tapered roller bearing outer race into housing





Fig. 3 Pulling off tapered roller bearing inner race
A - Kukko 44/2 two-arm puller





Fig. 4 Pressing on tapered roller bearing inner race
CAUTION! Wear protective gloves.

^ Heat inner race to approximately 100°C, place on and then press on





Fig. 5 Pulling off double tapered roller bearing inner race
^ Before installing, set 40-105 thrust piece onto differential housing.





Fig. 6 Pressing on double tapered roller bearing inner race

CAUTION! Wear protective gloves.

^ Heat inner race to approximately 100°C, place on and then press on.





Fig. 7 Driving out large tapered roller bearing outer race from cover
^ Check adjustment shims for damage after removing.





Fig. 8 Pressing in large tapered roller bearing outer race into cover





Fig. 9 Driving out ring gear from housing





Fig. 10 Installing ring gear

CAUTION! Wear protective gloves.

^ Guide ring gear with centering pins -A- (local manufacturer) when installing ring gear.
^ Heat inner race to approximately 100°C and insert.





Fig. 11 Install differential bevel gears
^ If the large differential bevel gears were replaced, adjustment shims must be re- determined see Fig. 12.
^ Insert large differential bevel gears with determined adjustment shims.
^ Install small differential bevel gears at 180° from their final position and rotate into place (arrow).
^ Install thrust washers and locate.
^ Install threaded pieces.
^ Drive in differential bevel gear shaft to final position and secure.





Fig. 12 Differential bevel gears, adjusting
^ Install large differential bevel gears with the thinnest shims (0.5 mm).
^ Install small differential bevel gears rotated by 180 together with thrust washers.

Note: Do not rearrange differential bevel gears and thrust washers again!

^ Drive in shaft for differential bevel gears.
^ Press small differential bevel gears toward outside.
^ Push large differential bevel gears in direction of arrow and check play.
^ Determine thickest possible shim that can still be inserted for large differential bevel gears on each side.
^ Select adjustment shims of same thickness.
^ Determine adjustment shims according to table.





Available adjustment shims:





Note: The adjustment is also correct when no more play is present and the differential bevel gears can just barely be rotated (arrow).