Differential, Disassembling and Assembling

5 Speed Automatic 01V

Differential, disassembling and assembling

Prepare the following special tools and test equipment:





- VW401 thrust plate
- VW402 thrust plate
- VW407 punch
- VW412 punch
- VW295 needle bearing drift
- VW408A punch





- VW442 thrust pad
- 40-21 sleeve
- 40-105 thrust piece
- 2050 thrust plate
- 3138 drift
- Kukko 44/2 two arm puller





- VAG1582 taper roller bearing puller





- VAG 1582/6





Notes:
- Secure final drive in assembly fixture.
- Replace both tapered roller bearings together.
- Adjustments are required when replacing components marked with 1).

1. Cover for final drive 1)
2. O-ring
^ Replace
^ Insert with oil
3. Final drive housing 1)
4. Adjustment shim "S1"
^ Note thickness
5. Tapered roller bearing outer race 1)
^ Driving out see Fig. 1
^ Pressing in see Fig. 2
6. Tapered roller bearing inner race 1)
^ Removing see Fig. 3
^ Pressing on see Fig. 4
7. Bolt (60 Nm) plus additional 45°
^ Replace
^ Assignment
^ Lightly tighten bolts then tighten diagonally to correct torque.
8. Differential housing 1)
9. Ring gear 1)
^ Is matched to Drive pinion (gear set)
^ Application according to transmission code letters
^ Drive from housing using mandrel see Fig. 9
^ Install onto differential housing see Fig. 10
10. Roll pin
^ For securing shaft for differential bevel gears
^ drive in flush
11. Double tapered roller bearing inner race 1)
^ Removing see Fig. 5
^ Pressing on see Fig. 6
12. Double tapered roller bearing outer race 1)
^ Driving out see Fig. 7
^ Pressing in see Fig. 8
13. Shim "S2"
^ Note thickness
14. Threaded piece
15. Large differential bevel gear
^ Installing see Fig. 11
^ Adjusting see Fig. 12
16. Small differential bevel gear
^ Installing see Fig. 11
17. Shaft for differential bevel gears
^ Drive out using drift
18. Adjustment shim
^ Redetermining thickness see 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





Fig. 3 Pulling off tapered roller bearing inner race
A - Kukko 44/2 two-arm puller





Fig. 4 Pressing on tapered roller bearing inner race

CAUTION: Wear protective gloves.

- Heat inner race to approximately 100°C, place on and then press on.





Fig. 5 Pulling off double tapered roller bearing inner race
- Before installing, set 40-105 thrust piece onto differential housing.





Fig. 6 Pressing on double tapered roller bearing inner race

CAUTION: Wear protective gloves.

- Heat inner race to approximately 100°C, place on and then press on.





Fig. 7 Driving out large tapered roller bearing outer race from cover
- Check adjustment shims for damage after removing.





Fig. 8 Pressing in large tapered roller bearing outer race into cover





Fig. 9 Driving out ring gear from housing





Fig. 10 Installing ring gear
CAUTION: Wear protective gloves.

- Guide ring gear with centering pins -A- (local manufacturer) when installing ring gear.
- Heat inner race to approximately 100°C and insert.





Fig. 11 Install differential bevel gears
- If the large differential bevel gears were replaced, adjustment shims must be redetermined see Fig. 12.
- Insert large differential bevel gears with determined adjustment shims.
- Install 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 Differential bevel gears, adjusting
- Install large differential bevel gears with the thinnest shims (0.5 mm).
- Install small differential bevel gears rotated by 180° together with thrust washers.

Note:
^ Do not rearrange differential bevel gears and thrust washers again!

- Drive in shaft for differential bevel gears.
- Press small differential bevel gears toward the outside.
- Push large differential bevel gears in direction of arrow and check play.
- Determine the thickest possible shim that can still be inserted for the large differential bevel gears on each side.
- Select adjustment shims of the same thickness.
- Determine adjustment shims according to table.





Available adjustment shims:





Note: The adjustment is also correct when no more play is present and the differential bevel gears can just barely be rotated (arrow).