Differential, Removing and Installing

Differential, removing and installing





Special tools and workshop equipment required
^ VW 771 Multi-purpose tool
^ 3257 Socket attachment SW 27
^ V.A.G 1331 Torque wrench
^ 1 - Kukko 21/3 Internal puller

Note:
^ Removal and installation is possible with transmission installed.
^ The differential can be removed and installed without removing selector mechanism, input shaft, drive pinion and transmission cover. Removal of the components above is necessary to adjust the differential.
^ Inspect polygon bearings for visible damage.
^ The polygon bearings can only be replaced together with flange shaft.
^ Rough running of the polygon bearings with flange shaft removed, does not indicate that bearings are defective. An acoustic test can only be performed installed.
^ A spacer ring is installed between the polygon bearing and the large differential bevel gear on flange shafts with 30 mm spline diameter Fig. 4, -item 5-.
^ Adjustments are required when replacing components marked 1) Adjustment overview.





1 - Transmission housing
2 - Sealing ring
^ Replacing
3 - Circlip Replace Removing and installing
4 - Spacer ring
^ Is only inserted on flange shafts with spline diameter of 30 mm.
^ Removing
^ Installing
5 - Flange shaft
^ Removing and installing
^ Assembling flange shaft
6 - Differential with ring gear 1)
^ Can be removed without removing gear cluster
^ Disassembling and assembling
7 - Cover for final drive
^ Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces
8 - Torx bolt - 25 Nm
9 - Speedometer drive wheel
^ Removing and installing
^ Carefully install the drive wheel onto the differential, make sure that it is kept straight. The drive wheel can break using excessive force.

Fig. 1 Removing and installing circlip:

- Clamp flange shaft in vice using soft jaws. Press out old circlip from groove in flange shaft use new circlip -A-.

Fig. 2 Removing spacer ring:

A - Internal puller 18.5... 23.5 mm, e.g. Kukko 21/3
- Pull out spacer ring using multi-purpose tool VW 771.

Fig. 3 Installing spacer ring:

- Drive new spacer ring home, take care not to bend ring.

Fig. 4 Assembling flange shaft:

1 - Flange shaft
2 - Needle bearing (polygon bearing)
3 - Spacer ring
4 - Spacer ring - additionally installed on shafts with 30 mm spline diameter
5 - Circlip

Note: The needle bearings (polygon bearings) do not turn easily when the flange shaft is removed. This does not indicate a bearing is faulty.