Differential, Disassembling and Assembling

Special tools, testers and auxiliary items required:
^ Drift VW295
^ Thrust plate VW401
^ Thrust plate VW402
^ Press tool VW412
^ Installing tool VW459/2
^ Thrust plate 30-205
^ Mandrel 30-505
^ Press tool 40-21
^ Thrust plate 40-105
^ Thrust pad 30-62
^ Drift 31-38
^ Taper roller bearing puller V.A.G 1582
^ Grip V.A.G 1582/3
^ Grip V.A.G 1582/6

Notes:
^ Removing and installing differential.
^ Adjustments are required when replacing components marked 1).





1. Transmission - housing 1)
2. Shim "S2"
^ Note thickness
^ Adjustment overview
3. Outer race for small taper roller bearing 1)
^ Driving out see Fig. 9
^ Driving in see Fig. 10
4. Inner race for small taper roller bearing 1)
^ Pulling out see Fig. 1
^ Pressing in see Fig. 3
^ Low friction bearing; do not oil when measuring frictional torque
5. Ring gear 1)
^ Paired with drive pinion (final drive set)
^ Removing see Fig. 5
^ Installing see Fig. 6
6. Differential - housing 1)
7. Ring gear bolt, 60 Nm - 45° further
^ Always replace
^ Use only genuine bolts
8. Inner race for large taper roller bearing 1)
^ Pulling off see Fig. 2
^ Pressing on see Fig. 4
^ Low friction bearing; do not oil when measuring frictional torque
9. Drive wheel
^ For speedometer sender
^ Removing and installing
^ Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use force; the drive wheel can break easily
^ Installation position: shoulder (arrow) towards differential
10. Outer race for large taper roller bearing 1)
^ Driving out see Fig. 11
^ Driving in see Fig. 12
11. Shim "S1"
^ Note thickness
^ Adjustment overview
12. Cover for final drive 1)
^ With O-ring
^ Replace O-ring
^ Oil O-ring before installing
13. Shims
^ Redetermining thickness see Fig. 8
14. Sun wheels
^ Adjusting see Fig. 8
15. Threaded - piece
16. Thrust washer
^ Check for cracks and chipping
17. Planet wheels
^ Installing see Fig. 7
18. Shaft for planet wheels
^ Drive out with drift after removing spring pin
^ Before driving in, align thrust washers
19. Spring pin
^ Drive in flush





Fig. 1 Pulling inner race for small taper roller bearing out of housing
- Fit thrust plate 40-105 before fitting puller.





Fig. 2 Pulling inner race for large taper roller bearing off housing
- Fit thrust plate 40-105 before fitting puller.





Fig. 3 Pressing on inner race for small taper roller bearing
- Heat bearing to approx. 100°C, fit in position and press home.





Fig. 4 Pressing on inner race for large taper roller bearing
- Heat bearing to approx. 100°C, fit in position and press home.





Fig. 5 Driving ring gear off housing





Fig. 6 Installing ring gear
- Use 2 centering pins -A- (local manufacture) as a guide.

CAUTION: Wear protective gloves.

- Heat ring gear to approx. 100°C and install.
- Allow the ring gear to cool off slightly before inserting the bolts. Then tighten to specified torque.





Fig. 7 Installing planet wheels and sun wheels
- Carefully lever out drive wheel for speedometer sender with a screwdriver.
- Insert thrust washers for planet wheels with a small amount of grease.
- Insert sun wheels with selected shims see Fig. 8.
- Insert planet wheels spaced 180° apart and rotate into position (arrow).
- Insert threaded pieces.
Installation position: stepped shoulder towards sun wheels
- Locate thrust washers and planet wheels so that they align with the holes.
- Drive planet pinion shaft into final position and secure.





Fig. 8 Adjusting planet wheels and sun wheels
- Insert sun wheels with thinnest shims (0.5 mm).
- Insert planet wheels with thrust washers and press in shaft.

Note: Do not now interchange bevel gears and thrust washers!

- Press planet wheels outwards and check play of sun wheels by hand (arrows).
- Adjust play by inserting an appropriate shim.
Specification: max. 0.10 mm





Note: The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the differential bevel gears (arrow).

- Determine shim from table.





The following shims are available:





Fig. 9 Driving outer race for small taper roller bearing out of transmission housing





Fig. 10 Driving outer race for small taper roller bearing into transmission housing





Fig. 11 Driving outer race for large taper roller bearing out of cover
- Use suitable base, e.g. VW 470 with recess towards cover.





Fig. 12 Driving outer race for large taper roller bearing into cover