Differential, Disassembling and Assembling
Special tools and equipment
^ VW295 needle bearing drift
^ VW401 thrust plate
^ VW402 thrust plate
^ VW407 punch
^ VW408A punch
^ VW447H thrust pad
^ VW4471 thrust pad
^ VW472/1 pressure piece
^ VW511 thrust pad
^ 30-11 thrust pad
^ 30-205 thrust pad
^ 40-21 sleeve
^ Thrust piece 40-105
^ Drift 3138
^ Press support 3144
^ Tube 3296
^ Sealant AMV 188 000 02
^ Kukko 20/10 two-arm puller or Kukko 44/2 puller
^ Kukko 204/2 two-arm puller
Notes:
^ Always replace both taper roller bearings together as a set.
^ Adjustments are required when replacing components marked 1).
1. Transmission - housing 1)
2. Shim "S2"
^ Note thickness
^ Adjustment overview
3. Outer race for small taper roller bearing right 1)
^ Driving out see Fig. 1
^ Pressing in see Fig 2
4. Inner race for small taper roller bearing right 1)
^ Pulling off see Fig. 3
^ Pressing on see Fig. 4
5. Ring gear 1)
^ Is mated to drive pinion (final drive set)
^ Allocate according to transmission code
^ Drive off housing with a drift see Fig. 9
^ Fitting on differential housing see Fig. 10
6. Differential housing 1)
7. Bolt, 60 Nm 1/4 turn further
^ Replace
^ Lightly tighten bolts then tighten diagonally to correct torque
8. Inner race for large taper roller bearing left 1)
^ Pulling off see Fig. 5
^ Pressing on see Fig. 4
9. Speedometer - drive wheel
^ Removing and installing
^ Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use force; the drive wheel can break easily.
10. Outer race for large taper roller bearing left 1)
^ Knocking out see Fig. 7
^ Pressing in see Fig. 8
11. Shim "S1"
^ Note thickness
^ Adjustment overview
12. Cover for differential 1)
^ Seal with AMV 188 000 02
13. Sun wheel
^ Installing see Fig. 11
14. Shaft for planet wheels
^ Knock out with drift after removing spring pin
15. Spring pin
^ For securing planet pinion axis shaft
^ Version with annular groove: removing and installing see Fig. 12
^ Version without annular groove: knock out with drift
16. Planet pinion
^ Installing see Fig. 11
17. One piece thrust washer
^ Coat with transmission oil when installing
Fig. 1 Knocking right taper roller bearing outer race out of transmission housing
- Turn webs -A- and -B- out until they sit on the outer race within the recess in transmission.
- After removing check shims for damage.
Fig. 2 Pressing right taper roller bearing outer race into transmission housing
- Press piece VW 472/1 is fitted with the cone in the outer race.
Fig. 3 Pulling off right taper roller bearing inner race
A - Two-arm puller, e.g. Kukko 20/10
Fig. 4 Pressing on right taper roller bearing inner race
WARNING: Wear protective gloves
- Heat inner race to approx. 100°C, place on and press in.
Fig. 5 Pulling off large taper roller bearing inner race
A - Two-arm puller, e.g. Kukko 204/2
Fig. 6 Pressing on left taper roller bearing inner race
WARNING: Wear protective gloves!
- Heat inner race to approx. 100°C, place on and press in.
Fig. 7 Knocking left taper roller bearing outer race out of cover
- Turn webs -A- and -B- out until they sit on the outer race within the recess in transmission.
- After removing check shims for damage.
Fig. 8 Pressing left taper roller bearing outer race into cover
- Press piece 2050 is fitted with the cone in the outer race.
Fig. 9 Knocking ring gear off housing
Fig. 10 Heat ring gear to approx. 100°C when installing
- When fitting ring gear, guide it with centralizing pins-A- (local manufacture).
CAUTION: Wear protective gloves.
- Allow the ring gear to cool off slightly before inserting the bolts. Then tighten to specified torque.
Fig. 11 Installing sun wheels and planet pinions
- Lubricate one-piece thrust washer with transmission oil and install.
- Insert sun wheels.
- Insert planet pinions at 180 from their final position, and then rotate into place -arrow-.
- Drive planet pinion axle into final position and secure.
Fig. 12 Removing and installing spring pin.
Removing
- Spring pin with annular groove: pull out using side-cutting pliers.
- Spring pin without annular groove: knock out from behind using a punch.
Installing
- Drive in spring pin as far as the stop.