Differential, Disassembling and Assembling
5 Speed A/T 01V
Differential, disassembling and assembling
Special tools and equipment
^ VW295 needle bearing drift
^ VW401 thrust plate
^ VW402 thrust plate
^ VW407 punch
^ VW408A punch
^ VW412 punch
^ VW442 thrust pad
^ 40-21 sleeve
^ 40-105 thrust pad
^ 2050 thrust plate
^ 3138 drift
^ Tapered roller bearing puller VAG1582 taper roller bearing puller
^ VAG1582/6 attachment to VAG1582
^ Kukko 44/2 two-arm puller
Notes
^ General repair notes, Refer to Automatic Transmission/Transaxle, Service and Repair
^ Replace both tapered roller bearings together. If possible, use same manufacturer!
^ Adjustments are required when replacing components marked with 1)Refer to Adjustment overview, Refer to Differential, Assembly, Adjustments
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. Small tapered roller bearing outer race 1)
^ Driving out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
6. Small tapered roller bearing inner race 1)
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 4
7. Bolt - tighten to 60 Nm and then tighten an additional 45-5°.
^ Always replace
^ Allocation
, Refer to Parts Supplier
^ Lightly tighten bolts then tighten diagonally to correct torque.
8. Differential housing 1)
9. Ring gear 4)
^ Matched to drive pinion (gear set)
^ Application according to transmission code letters
Refer to Parts Supplier
^ Press off of housing using drift, Refer to Fig. 9
^ Install on differential housing, Refer to Fig. 10
10. roll pin
^ For securing shaft for differential bevel gears
^ Drive in flush
11. Large tapered roller bearing inner race A)
^ Pulling off, Refer to Fig. 5
^ Pressing on, Refer to Fig. 6
12. Large tapered roller bearing outer race 1)
^ Driving out, Refer to Fig. 7
^ Pressing in, Refer to Fig. 8
13. Adjustment shim "S1 "
^ Note thickness
^ List of adjustments, Refer to Differential, Assembly, Adjustments
14. Threaded piece
15. Large differential bevel gear
^ Installing, Refer to Fig. 11
^ Adjusting, Refer to Fig. 12
16. Small differential bevel gear
^ Installing, Refer to Fig. 11
17. Shaft for differential bevel gears
^ Drive out using drift
^ Drive in carefully so as not to damage thrust washers.
^ Secure with locking pin Item 10
18. Adjustment shim
^ Re-determine thickness, Refer to 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
- Install outer race with VW295 needle bearing drift by tapping lightly using hammer.
- Then drive in to stop, as shown in illustration.
Fig. 3 Pulling off small tapered roller bearing inner race
A - Kukko 44/2 two-arm puller
Fig. 4 Pressing on small tapered roller bearing inner race
WARNING: Wear protective gloves!
- Heat inner race to approximately 100°C ,position and press on.
Fig. 5 Pulling off large tapered roller bearing inner race
- Before installing removal tool, set 40-105 thrust piece onto differential housing.
Fig. 6 Pressing on large tapered roller bearing inner race
WARNING: Wear protective gloves!
- Heat inner race to approximately 100°C Position and press on.
Fig. 7 Driving large tapered roller bearing outer race out of cover
- Check adjustment shims for damage after removing.
Fig. 8 Pressing large tapered roller bearing outer race into cover
Fig. 9 Driving out ring gear from housing
Fig. 10 Installing ring gear
WARNING: Wear protective gloves!
- When installing ring gear, guide with centering pins -A- (self-made).
- Heat ring gear to approximately 100°C and position.
Fig. 11 Installing small differential bevel gears
- If the large differential bevel gears were replaced, adjustment shims must be redetermined, Refer to Fig. 12.
- Insert large differential bevel gears with determined adjustment shims.
- Insert 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 Adjusting differential bevel gears
- Install large differential bevel gears with the thinnest shims (0.5 mm).
- Insert small differential bevel gears 180° from final position together with thrust washers.
Note: Do not rearrange differential bevel gears and thrust washers again!
- Drive in shaft for differential bevel gears.
- Press the small differential bevel gears toward the outside.
- Push large differential bevel gears in direction of arrow and check play.
- Determine the largest possible shim that can still be installed for the large differential bevel gears on each side.
^ Adjustment shims should be the same thickness on both sides.
- Determine adjustment shims according to table. Part numbers
Refer to Parts Supplier
Available adjustment shims:
Note: The adjustment is also correct when no more play can be felt, but the differential bevel gears can just barely be rotated (arrow).