Differential, Removing and Installing

5 Speed A/T 01V

Differential, removing and installing

Notes
^ General repair notes, Refer to Automatic Transmission/Transaxle, Service and Repair.
^ Secure final drive to assembly stand.
^ Adjustments are required when replacing components marked with 4)Refer to Adjustment overview, Refer to Differential Assembly, Adjustments.





1. Breather sleeve
^ With rubber valve
^ Installed position Item
2. Final drive housing 1)
^ With drive pinion
^ Drive pinion, removing and installing Drive Pinion, Removing, Installing, Disassembling and Assembling
3. Large tapered roller bearing outer race 1)
^ Driving out, Refer to Differential, Disassembling and Assembling, See Fig. 7
^ Pressing in, Refer to Differential, Disassembling and Assembling, See Fig 8
4. Adjustment shim "S1"
^ Note thickness
^ Adjustment overview, Refer to Differential Assembly, 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
^ Always replace, Refer to Seals and Gaskets, Differential
8. Socket head bolt - 25 Nm
9. Right drive flange
^ Removing and installing , Refer to Fig. 1
10. Oil filler plug - 35 Nm
11. Differential with ring gear 4)
12. Oil drain plug - 35 Nm
13. Socket
^ Holds the magnet in position
^ Press in until stop
14. Magnet
15. Small tapered roller bearing outer race 1)
^ Driving out, Refer to Differential, Disassembling and Assembling, See Fig. 1
^ Pressing in, Refer to Differential, Disassembling and Assembling, See Fig 2
16. Shim S2
^ Note thickness
^ List of adjustments, Refer to Differential Assembly, Adjustments
17. Left gasket
^ Always replace, Refer to Seals and Gaskets, Differential
18. Left drive flange
^ Removing and installing , Refer to Fig.1
19. Socket head bolt - 25 Nm
20. Cover
^ Installing , Refer to Fig.2





Fig. 1 Removing and installing drive flange
- To loosen securing bolt, thread 2 bolts into drive flange and counter hold using tire iron.
- Remove drive flange at installed bolts.





Fig. 2 Press in cover up to stop





Fig. 3 Installed 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.

Differential, removing and installing
^ Rear final drive removed

Special tools and equipment





^ VAG1306 drip tray

Removing
- Secure complete rear final drive to assembly stand.
- Place VAG1306 drip tray underneath and drain gear oil.





- Remove left and right drive flanges.
- To loosen securing bolt, thread 2 bolts into drive flange and counter hold using tire iron.
- Mark left and right drive flanges.
- Remove drive flange at installed bolts.
- Remove mounting bolts for final drive cover.
- Remove final drive cover from axle housing and remove differential.

Installing
Installation is reverse of removal, noting the following:
- 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.
- Replace drive flange seals, Refer to Seals and Gaskets, Differential
- Fill gap between sealing lip and dust lip with multi-purpose grease.





- Install drive flanges and tighten to 25 Nm.
- Top-up and check gear oil in rear final drive.