Differential, Disassembling and Assembling
Differential, disassembling and assembling
The following special tools and testing devices are required:
- Thrust plate VW 401
- Thrust plate VW 402
- Press tool VW 407
- Press tool VW 412
- Drift VW 295
- Press tool VW 408 A
- Thrust pad VW 442
- Sleeve 40-21
- Thrust plate 40-105
- Thrust pad 2050
- Drift 3138
- Two-arm puller Kukko 44/2
- Taper roller bearing extractor V.A.G 1582
- V.A.G 1582/6
Notes:
^ General repair instructions.
^ Secure final drive on a repair stand.
^ Replace both taper roller bearings together.
^ When replacing the parts marked with 1) adjustment work is required; Refer to Adjustment overview.
1. Cover for final drive 1)
2. O-ring
^ Replace
^ Insert with oil
3. Final drive housing 1)
4. Shim "S1 "
^ Note thickness
^ Refer to Adjustment overview
5. Outer race for small taper roller bearing 1)
^ Tapping out; Refer to Fig. 1
^ Pressing in; Refer to Fig. 2
6. Inner race for small taper roller bearing 1)
^ Pulling off; Refer to Fig. 3
^ Pressing on; Refer to Fig 1
7. Bolt - 60 Nm - turn 45° further
^ Replace
^ Allocation
^ Parts List
^ Lightly tighten bolts then tighten diagonally to specified torque.
8. Differential housing 1)
9. Ring gear 1)
^ Paired with pinion shaft (final drive set)
^ Allocation based on transmission code letters
^ Parts List
^ Drive off housing with a drift; Refer to Fig. 9
^ Install to differential housing; Refer to Fig. 10
10. Spring pin
^ For securing shaft for bevel gears
^ Drive in flush
11. Inner race for large taper roller bearing 1) Pulling off; Refer to Fig. 5
^ Pressing on - F"
12. Outer race for large taper roller bearing 1) Tapping out; Refer to Fig. 7 Pressing in F"
13. Shim "S2" Note thickness
14. Threaded piece
15. Large bevel gear Installing; Refer to Fig. 11 Adjusting; Refer to Fig. 12
16. Small bevel gear
^ Installing; Refer to Fig. 11
17. Shaft for planet wheels
^ Drive out with drift
18. Adjustment shim
^ Redefine thickness; Refer to Fig. 12
19. Thrust washer
^ Check for cracks
Fig. 1 Driving out small taper roller bearing outer race of cover
- After removing check shims for damage.
Fig. 2 Pressing in taper roller bearing outer race small until stop into housing
Fig. 3 Pulling off inner race for small taper roller bearing
A - Two arm puller, e.g. Kukko 44/2
Fig. 4 Pressing on small taper roller bearing inner race
WARNING!: Wear protective gloves!
- Heat the inner race to approximately 100°C, position and push to final position.
Fig. 5 Pulling off inner race for large taper roller bearing
- Install thrust plate 40-105 onto differential housing before fitting puller.
Fig. 6 Pressing on large taper roller bearing inner race
WARNING!: Wear protective gloves!
- Heat the inner race to approximately 100°C, position and push to final position.
Fig. 7 Driving out outer race for large taper roller bearing out of cover
- After removing check shims for damage.
Fig. 8 Pressing in outer race for large taper roller bearing into cover
Fig. 9 Driving ring gear off housing
Fig. 10 Installing ring gear
WARNING!: Wear protective gloves!
- Locate ring gear guide with centering pins -A- (self-produced) when mounting.
- Heat the ring gear to approximately 100°C and position.
Fig. 11 Installing small bevel gears
- If large bevel gears have been replaced, measure and select new shims; Refer to Fig. 12.
- Insert large bevel gears with recalibrated shims.
- Insert small bevel gears spaced 180* apart, and then rotate into place -arrow-.
- Insert washers and align.
- Insert threaded pieces.
- Drive small bevel gear shaft into final position and secure.
Fig. 12 Adjusting differential bevel gears
- Insert large bevel gears with thinnest shims (0.5 mm).
- Insert small bevel gears at a 180° offset with thrust washers.
Note: Do not now interchange bevel gears and thrust washers.
- Drive in shaft for bevel gears.
- Press small bevel gears outwards.
- Press large bevel gears in direction of arrow and check play.
- Ascertain the thickest - just fitting - shim for the large bevel gears on each side.
- Select required shims from table. Part numbers
Refer to Part Supplier
The following shims are available
Note: The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the differential bevel gears -arrow-.