Differential, Removing and Installing

Differential, removing and installing





Special tools and equipment
^ VW 771 Multi-purpose tool
^ 3257 6 mm Allen key extension
^ VAG 1331 Torque wrench
^ 1 - Kukko 21/3 Internal puller

Note:
^ The differential can also be removed and installed with the transmission installed.
^ The differential can be removed and installed without disassembling the transmission, input shaft, pinion or transmission housing. The above-mentioned parts must be disassembled if the differential is to be adjusted.
^ Watch out for visible damages to the polygonal bearings.
^ Polygonal bearings can only be replaced together with drive flange.
^ Polygonal bearings run roughly when drive flange is not installed. This does not indicate faulty bearings. An acoustic test can only be conducted when drive flange is installed.
^ Drive flanges with a splined shaft diameter of 30 mm have a spacer ring installed between polygonal bearing and bevel gear.
^ When replacing parts marked 1) adjustments are required = Adjustment table.





1 - Transmission housing
2 - Oil seal
^ Replacing
3 - Circlip
^ Replace
^ Removing and installing
4 - Spacer ring
^ Only installed on drive flanges with polygonal bearings and splined diameter 30 mm
^ Removing
^ Installing
5 - Drive flange
^ Removing and installing
^ Drive flange assembly
6 - Differential with ring gear 1)
^ Can also be removed without removing manual transmission
^ Disassembling and assembling
7 - Final drive cover
^ Apply a thin coat of sealing paste AMV 188 001 02 to sealing surfaces
8 - TORX bolt, 25 Nm
9 - Speedometer driving gear
^ Removing and installing
^ Mount on differential carefully and without tilting. Do not use force, the driving gear could break

Fig. 1 Removing and installing circlip:

- Clamp drive flange with soft jaws in vice. Press circlip out of drive flange groove using new circlip -A-.

Fig. 2 Removing spacer ring:

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

Fig. 3 Installing spacer ring:

- Push spacer ring in as far as it will go, ensuring it is not askew.

Fig. 4 Drive flange assembly with polygonal bearings:

1 - Drive flange
2 - Needle bearing (polygonal bearing)
3 - Spacer ring
4 - Spacer ring - additionally installed if splined shaft diameter = 30 mm
5 - Circlip

Note: Needle bearings (polygonal bearings) do not move freely when drive flange is removed. This does not indicate faulty bearings.