Differential, Disassembling and Assembling
Differential, disassembling and assembling
Special tools and workshop equipment required
^ V.A.G 1582 Puller
^ V.A.G 1582/3 Grip
^ VW 412 Press tool
^ 40-105 Thrust plate
^ VW 401 Press plate
^ VW 402 Press plate
Special tools and workshop equipment required
^ VW 408 A Press tool
^ VW 473 Thrust piece
^ 30 205 Thrust plate
^ 3144 Sleeve
^ VW 401 Press plate
^ 2007 Thrust pad
Notes:
^ Heat taper roller bearing inner race to 100°C before installing.
^ Always replace both taper roller bearings together as a set.
^ If the taper roller bearings, differential housing, transmission housing or clutch housing are replaced, always adjust the differential.
1. Transmission housing
2. Bolt
3. Differential housing
^ Bolt to final drive gear
4. Final drive gear
^ Riveted in production
^ Is paired with output shaft - replace only as a set
^ Pressing off - Fig. 9
^ Installation position , Refer to Fig. 10
^ Heat to 100°C before installing
^ Fit to differential housing - Fig. 11
^ Bolted - Fig. 12
5. Backing plate
6. Nut, 70 Nm
7. Shim
^ For differential
^ Determining thickness, Refer to Differential Assembly, Adjusting
8. Taper roller bearing outer race
^ Pulling out, Refer to Fig. 5
^ Pressing in, Refer to Fig 6
9. Taper roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 4
10. Differential housing
^ With riveted final drive gear
^ When replacing final drive gear drill out rivet heads
^ Attaching final drive gear with bolts
11. Speedometer drive wheel
^ Fit on differential housing as far as stop before pressing on inner race
12. Taper roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 4
13. Taper roller bearing outer race
^ Knocking out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
14. Clutch housing
15. Sleeve
16. Oil seal
17. Cone head bolt, 25 Nm
^ Bolt into threaded piece (item 25)
18. Flange shaft
19. Spring for flange shaft
^ Installed behind flange shafts
20. Thrust washer
^ Installation position: shoulder toward spring, tongue toward tapered ring
21. Tapered ring
^ With grooves to secure thrust washer
^ Installation position: taper toward differential housing
22. Circlip
^ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
23. One - piece thrust washer
^ Coat with transmission oil when installing
24. Sun wheel
^ Installing, Refer to Fig. 14
25. Threaded piece
^ Installing, Refer to Fig. 14
26. Planet pinion axis shaft
^ Knock out with drift
^ Installing, Refer to Fig. 14
27. Spring pin
^ For securing planet pinion axis shaft
^ Removing and installing, Refer to Fig. 13
28. Planet pinion
^ Installing, Refer to Fig. 14
29. Sun wheel
^ Installing, Refer to Fig. 14
Fig. 1 Knocking taper roller bearing outer race out of clutch housing
- First remove flange shaft seal mounting sleeve on transmissions with springs behind flange shaft.
Fig. 2 Pressing taper roller bearing outer race into clutch housing
No shim is installed in the clutch housing end.
Fig. 3 Pulling off taper roller bearing inner race
- Before fitting the extractor position press piece 40105 on differential housing.
Notes: Both both taper roller bearing inner races are pulled off the differential housing in the same way.
Fig. 4 Pressing on taper roller bearing inner race
Notes: The taper roller bearing inner races for transmission housing and clutch housing are pressed on with the same press tools.
Fig. 5 Pulling taper roller bearing outer race out of transmission housing
A-Counter support, e.g. Kukko 22/2
B-Internal puller46-58 mm, e.g. Kukko 21/7
Fig. 6 Pressing taper roller bearing outer race into transmission housing
- Fit shim under outer race.
- Support transmission housing with sleeve 3144 directly below bearing mounting.
Fig. 7 Both sides of differential housing are chamfered (arrow) to accept tapered rings/springs
Fig. 8 Drilling out rivet heads
- Drill out rivet heads with 12 mm drill from countersunk side and knock - out with drift.
Notes: Clean differential before and after drilling. Cover taper roller bearings to protect from debris.
Fig. 9 Pressing off final drive gear
- Place thrust piece 40-105 on differential housing.
Fig. 10 Installation position of final drive gear
Circular groove - A - faces toward bolt - on side of differential.
Fig. 11 Heating final drive gear to approximately 100°C and installing
- Use bolts - A - from repair kit to guide final drive gear into position during installation.
Fig. 12 Bolting final drive gear and differential housing together
Use special bolts with plates and nuts according to Parts Supplier.
Fig. 13 Removing and installing planet wheel axis shaft spring pin
Removing
- Cover taper roller bearing inner race and speedometer drive gear to avoid possible damage and protect from metal particles.
- Knock - out spring pin with chisel, inserting chisel into circumferential groove.
Installing
- Knock fully into the differential housing.
Fig. 14 Installing sun wheels and planet pinions
- Lubricate one piece thrust washer with transmission oil and install.
- Install both sun wheels and secure (e.g. with flange shaft).
- Insert planet wheels (180� apart) and pivot into position.
- Push planet wheel axis shaft (arrow - A -) in until first planet wheel is contacted.
- Position threaded pieces (arrow- B -) in sun wheels. Installation position: step toward sun wheel
- Drive planet wheel axis shaft into final position and secure with spring pin.