Differential, Disassembling and Assembling

Differential, disassembling and assembling

Special tools and workshop equipment required
^ VW 295 Drift
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 412 Thrust tool
^ Installation and removal tool VW 459
^ VW 470 Thrust ring for drive pinion bearings

^ 30-205 Thrust plate
^ 30-505 Fitting mandrel
^ 40-21 Thrust sleeve
^ 40-105 Thrust plate
^ 3062 Thrust disk
^ 3138 Driver

^ VAG 1582 Taper roller bearing puller
^ VAG 1582/3 Grip piece
^ VAG 1582/6 Grip piece

1 - Transmission housing
2 - Shim S2
^ Note thickness
^ Adjustment overview
3 - Taper roller bearing outer race, small 1)
^ Tapping out
^ Tapping in
4 - Taper roller bearing inner race, small 1)
^ Pulling off
^ Pressing on
^ Adjustments are required if these components are replaced go to Adjustment overview.
5 - Ring gear 1)
^ Paired with pinion shaft (final drive set)
^ Allocated according to transmission code letters from Parts Supplier
^ Drive off with a drift
^ Fit to differential housing
6 - Differential housing 1)
7 - Ring gear bolts - 60 Nm plus additional 45° turn
^ Always replace
^ Use only the original bolts
8 - Taper roller bearing inner race, large 1)
^ Pulling off
^ Pressing on
9 - Speedometer trigger wheel
^ Removing and installing
^ Installation position: Shoulder -arrow- faces toward differential; do not cant drive pegs in recess of differential housing
10 - Taper roller bearing outer race, large 1)
^ Tapping out
^ Tapping in
11 - Shim S1
^ Note thickness
^ Adjustment overview
12 - Cover for final drive
^ With O-ring
^ Replace O-ring
^ Lubricate O-ring before installing
13 - Adjustment shim
^ Redefine thickness
14 - Large bevel gear
^ Installing
^ Adjusting
15 - Threaded piece
16 - Thrust washer
^ Check for cracks and chipping
17 - Small bevel gear
^ Installing
^ Adjusting
18 - Shaft for small bevel gears
^ Drive out with drift after removing spring pin
^ Before driving in, align thrust washers

19 - Roll pin
^ Replace
^ Drive in flush

Fig. 1 Removing inner race for small taper roller bearing:

- Install thrust plate 40-105 onto differential housing before installing puller.

Fig. 2 Removing inner race for large taper roller bearing:

- Remove speedometer trigger wheel
- Install thrust plate 40-105 onto differential housing before installing puller.

Fig. 3 Pressing on inner race for small taper roller bearing:

- Heat inner race to approximately 100°C, position and install.

WARNING: Wear protective gloves!

Fig. 4 Pressing on inner race for taper roller bearing:

- Heat inner race to approximately 100°C, position and install.

WARNING: Wear protective gloves!

Fig. 5 Driving ring gear off housing:

Fig. 6 Heat the ring gear to approximately 100 Degrees C and install.:

- When installing ring gear guide it on centering pins -A- (locally made).

WARNING: Wear protective gloves!

- Allow the ring gear to cool off slightly before inserting the bolts. Then tighten to the specified torque.

Fig. 7 Installing bevel gears:

- Insert thrust washers for small bevel gear with a small amount of grease.
- Insert large bevel gears with correct shims
- Insert planet pinions turned through 180° and pivot into position (arrow).
- Insert threaded pieces.
^ Installation position: Step toward large bevel gear

- Align thrust washers with hole.
- Drive small bevel gear shaft into final position and secure.

Fig. 8 Adjusting differential bevel gears:

- Insert large bevel gears with thinnest shims (0.5 mm).
- Insert small bevel gears with thrust washers and press in shaft.

Note: Do not now interchange large bevel gears and thrust washers.

- Press small bevel gears outward and check play of large bevel gears by hand -arrows-.
- Adjust play by inserting an appropriate shim.
^ Specification: no more than 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-.
Allocate shims using spare part catalog.

The following shims are available
Part numbers:
go to Parts Supplier

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

Fig. 10 Pressing 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 toward cover.