Differential, Disassembling and Assembling
Differential, disassembling and assembling
Special tools and equipment
^ VW 353 transmission support
^ VW 401 pressure plate
^ VW 402 pressure plate
^ VW 407 punch
^ VW 408 A punch
^ VW 412 thrust disc
Special tools and equipment
^ 40 105 thrust piece
^ 3005 thrust pad
^ 3259 tube
^ 3296 tube
^ 3345 press tool
^ V.A.G 1332 torque wrench
Special tools and equipment
^ V.A.G 1582 tapered roller bearing puller
^ V.A.G 1582/6 gripping piece
^ 1 Kukko 21/7 puller
^ 2 Kukko 18/0 puller unit
^ 3 Kukko 17/1 separating unit
^ 4 Kukko 22/2 support
Notes:
^ Heat inner ring/tapered roller bearing to 100°C before installation.
^ Replace tapered roller bearings together.
^ Adjust differential when replacing tapered roller bearings, differential housing, transmission housing and clutch housing.
1. Transmission housing
2. Bolt
3. Differential housing
^ Bolt to pinion for final drive
4. Pinion for final drive
^ Riveted in series
^ Press off
^ Installation position: ground surface points in direction of bolting surface of differential housing
^ Heat to 100°C before installation
^ Set onto differential housing, Refer to Fig 9
^ Bolted, Refer to Fig. 10
5. Backing plate
6. Nut, 40 Nm - additional 45�
7. Clutch housing
8. Adjustment shim
9. Tapered roller bearing outer race
^ Pulling off
^ Pressing in, Refer to Fig. 6
10. Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 4
11. Differential housing
^ With pinion gear for final drive riveted on
^ Drill out rivet heads for replacement of pinion gear for final drive
^ Secure pinion gear for final drive with bolts, Refer to Fig. 10
12. Tapered roller bearing inner race
^ Pulling off , Refer to Fig. 3
^ Pressing on
13. Tapered roller bearing outer race
^ Pulling off, Refer to Fig. 1
^ Pressing in , Refer to Fig. 2
14. Disk
^ Always 0.65 mm thickness
15. Connection sleeve for angled transmission
^ Pressed onto differential housing
^ Only pull off and press on with differential housing removed
^ Pulling off, Refer to Fig. 13
^ Pressing on, Refer to Fig. 14
16. Sealing washer
17. Angled transmission
18. Hex bolt
* 40 Nm + additional 45°
19. Disc
20. Tapered bolt, 25 Nm
^ Bolt to threaded piece (-29-)
21. Drive flange, right
22. O-ring
^ Always replace
23. O-ring
^ Always replace
24. O-ring
^ Always replace
25. Large differential bevel gear
^ Installing, Refer to Fig. 12
26. Differential bevel gear axle
^ Drive out with drift
^ Installing, Refer to Fig. 12
27. Roll pin
^ For securing axle for differential bevel gears
^ Removing and installing, Refer to Fig. 11
28. Small differential bevel gear
^ Installing, Refer to Fig. 12
29. Threaded piece
^ Installing, Refer to Fig. 12
30. Thrust plate connection
^ Install with transmission oil
31. Securing ring
^ Holds tapered ring, thrust plate and pressure spring in position with drive flange removed
32. Tapered ring
^ With grooves for thrust plate engagement
^ Installation position: taper for differential housing
33. Thrust plate
^ Installation position: collar to pressure spring, ribs to threaded ring
34. Pressure spring for drive flange
^ Installed behind drive flanges.
35. Left drive flange
36. Seal
Fig. 1 Removing tapered roller bearing outer race from clutch housing
A - Support, i.e. Kukko 22/2
B - Puller 4658 mm, i.e. Kukko 21/7
Notes: After pulling out, check shim for damage and replace if necessary.
Fig. 2 Installing tapered roller bearing outer race on clutch housing
- Insert shim before.
Fig. 3 Removing tapered roller bearing inner race
- Place 40-105 pressure actuator onto differential housing before installing puller.
Notes: Removing of both tapered roller bearing inner races from differential housing is identical.
Fig. 4 Installing tapered roller bearing inner race
Notes: Tapered roller bearing inner races for transmission housing and clutch housing are pressed on using the same pressing tools.
Fig. 5 Removing tapered roller bearing outer race from transmission housing
A - Support, i.e. Kukko 22/2
B - Inner puller 46...58 mm, i.e. Kukko 21/7
Fig. 6 Installing tapered roller bearing outer race into transmission housing
- Support transmission housing with 3345 press tool directly below bearing support.
Fig. 7 Drilling out rivet heads
- Drill out rivet heads on countersunk side using a 12 mm drill bit and drive out rivet using a mandrel.
Notes: Clean differential before and after drilling out, protect tapered roller bearings from drilling shavings.
Fig. 8 Removing final drive pinion gear
- Set 40 105 pressure actuator onto differential housing.
Fig. 9 Heat up final drive pinion gear to approximately 100°C and install
- Guide final drive pinion gear with bolts - A - from repair set.
Fig. 10 Bolt final drive pinion gear to approximately - A - to differential housing - B
- Use special bolts -1- with mounting plates -2- and nuts -3- according to Parts Supplier.
Fig. 11 Removing and installing roll pin for differential bevel gear axle
Removing
- Cover tapered roller bearing inner race to avoid possible damage and intrusion of shavings.
- Drive out roll pin using mandrel by inserting in surrounding notch.
Installing
- Drive into differential housing until stop.
Fig. 12 Installing differential bevel gears
- Insert thrust plate connection with transmission oil.
- Insert and secure both large differential bevel gears (i.e. with drive flange).
- Install small differential bevel gears 180° from their final position and pivot into place.
- Drive in differential bevel gear shaft (arrow - A -) to first small differential bevel gear.
- Insert threaded pieces (arrows - B -) in large differential bevel gears Installation position: shoulder to differential bevel gear.
- Drive in differential bevel gear shaft to end position and secure with roll pin.
Fig. 13 Removing connecting sleeve
A- Connecting sleeve
B - Puller, i.e. Kukko 18/1
C - Separator 12...75 mm, i.e. Kukko 17/1
Fig. 14 Pressing on connecting sleeve - A - for angled transmission