Differential Gear, Disassembling and Assembling

Notes:

^ Refer to general repair instructions.
^ Make sure both tapered roller bearings on file differential gear are replaced together. If possible, use bearings from same manufacturer.






1 - Final drive cover
2 - O-ring for cover
^ Always replace
3 - Final drive housing
4 - Shim S1
^ Note thickness
5 - Outer race of small tapered roller bearing
^ Driving out go to Fig. 10
^ Driving in Fig. 11
6 - Inner race of small tapered roller bearing
^ Pulling off go to Fig. 2
^ Pressing on go to Fig. 4
7 - Ring gear bolt
^ Always replace
^ Use only genuine replacement bolts
^ Counter-hold when tightening
^ Tighten in diagonal sequence
^ Tightening torque: 60 Nm (44 ft. lbs.) plus additional 1/8 turn (45°)
8 - Differential gear housing
9 - Ring gear
^ Matched with pinion (in ring gear and pinion set)
^ When replacing set, pinion and ring gear must be adjusted
^ Drive out of differential gear housing using mandrel go to Fig. 5
^ Installing go to Fig. 6
^ To install, warm ring gear to 100°C (212°F)
10 - Clamping sleeve
^ Drive in flush
11 - Inner race of large tapered roller bearing
^ Pulling off go to Fig. 1
^ Pressing on go to Fig. 3
12 - Outer race of large tapered roller bearing
^ Driving out go to Fig. 12
^ Driving in go to Fig. 13
13 - Shim S2
^ Note thickness
14 - Threaded piece
15 - Differential bevel gears, large
^ Adjusting Figs. 8 and 9
16 - Differential bevel gears, small
^ Installing go to Fig. 7
17 - Axle for differential bevel gears
^ Drive in using mandrel
^ Drive in carefully so that thrust washers do not get damaged
^ Secure with clamping sleeve
18 - Shim
^ Determine thickness again go to Figs. 8 and 9
19 - Thrust washer
^ Check for cracks and breakage

Fig. 1 Pulling off inner race of large tapered roller bearing






^ Place thrust piece 40-105 on differential gear housing before installing pulling device.

Fig. 2 Pulling inner race of tapered roller bearing off of housing






A- Two-arm puller (standard commercial), e.g. Kukko 44/2

Fig. 3 Installing inner race of large tapered roller bearing






^ Warm bearing to approximately 100°C (212°F), install and press down.

Fig. 4 Installing inner race of small tapered roller bearing






^ Warm bearing to approximately 100°C (212°F), install and press down.

Fig. 5 Driving ring gear off of housing






Fig. 6 Installing ring gear






^ Warm ring gear to approximately 100°C (212°F) and install.
A - Centering pins (hand-made); use as guide

Fig. 7 Installing differential bevel gears






^ Install large differential bevel gears together with proper shim go to Figs. 8 and go to 9.
^ Install small differential bevel gears (turned 180�) and swing in (hold thrust washer in place with some grease).
^ Align thrust washers.
^ Install threaded pieces.
^ Drive axle in and secure.

Fig. 8 Adjusting differential bevel gears






^ Install large differential bevel gears together with thinnest shims (0.5 mm).
^ Install small differential bevel gears together with thrust washers and press in axle.

From this point on, the differential bevel gears must be kept together with their respective thrust washers.
^ Press small differential bevel gears outward and check play of large differential bevel gears by hand (arrows).
^ Adjust play by installing an appropriate shim so that maximum play of 0.01 mm occurs.

Notes:

^ The adjustment is also correct if no play is perceptible but it is still possible to turn the differential bevel gears - Fig. 9.
^ For available shims go to parts catalog microfiche.

Fig. 9 Turning differential bevel gears






Fig. 10 Driving outer race of small tapered roller bearing out of final drive housing






Note: The shim(s) are damaged when removed.

Fig. 11 Driving outer race of small tapered roller bearing into final drive housing






^ Install outer race uniformly using VW 295, using light hammer taps.
^ Drive in to stop as shown in illustration.

Fig. 12 Driving outer race of large tapered roller bearing out of cover






Note:

- The shim(s) are damaged when removed.

Fig. 13 Pressing outer race of large tapered roller bearing into cover