Differential, Disassembling and Assembling
Differential, disassembling and assembling
Special tools and workshop equipment required
^ VW 401 Pressure plate
^ VW 402 Pressure plate
^ VW 407 Press tool
^ VW 408 A Press tool
^ VW 447 H Thrust pad
^ VW 447 I Thrust pad
Special tools and equipment
^ VW 472/1 Pressure piece
^ 2050 Pressure piece
^ 3138 Punch-out tool
^ 3144 Sleeve
^ 3296 Pipe
^ VAG 1332 Torque wrench
Special tools and equipment
^ VW 459 Pressing-out and pressing in tool
^ 1 - Kukko 21/7 Internal puller
^ 3 - Kukko 204/2 Puller
^ 4 - Kukko 22/2 Counter-support
^ Kukko 44-2 Two-arm puller
Note:
^ Removing and installing differential.
^ Replace both tapered roller bearings together
^ When replacing parts marked 1) adjustments are required go to Adjustment table.
1 - Transmission housing
2 - Shim S2
^ Make note of thickness
^ Adjustment table
3 - Outer race for right tapered roller bearing
^ Extracting
^ Pressing in
4 - Inner race for right tapered roller bearing
^ Pulling off
^ Pressing on
5 - Ring gear 1)
^ Paired with pinion (drive unit)
^ Assigning by way of transmission code letters using Parts catalog
^ Driving out of housing using mandrel
^ Installing to differential housing
6 - Differential housing 1)
^ Assigning by way of transmission code letters using Parts catalog
^ Assignment
go to Parts catalog
7 - Bolt - 60 Nm plus additional 45° turn
^ Always replace
^ Screw in bolts evenly and tighten to torque in diagonal sequence
8 - Inner race for left tapered roller bearing
^ Pulling off
^ Pressing on
^ Assignment
go to Parts catalog
9 - Speedometer driving gear
^ Removing and installing
^ Mount on differential carefully and without tilting. Do not use force, the driving gear could break
10 - Outer race for left tapered roller bearing 1)
^ Driving out
^ Pressing in
^ Assignment
go to Parts catalog
11 - Shim S1
^ Make note of thickness
^ Adjustment table
^ Assignment
go to Parts catalog
12 - Final drive cover
^ Apply a thin coat of sealing paste AMV 188 001 02 to sealing surfaces
^ Assignment
go to Parts catalog
13 - Large bevel gear
^ Installing
14 - Differential bevel gear shaft
^ Drive out with mandrel after removing spring pin
15 - Spring pin
^ For securing bevel gear shaft
^ With circumferential groove: Removing and installing
^ Without circumferential groove: Drive out with mandrel
16 - Small bevel gear
^ Installing
17 - One-piece thrust washer
^ Apply gear oil on insertion
Fig. 1 Extracting tapered roller bearing outer race from transmission housing:
A - Counter-support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
^ Check shims for damage after removal.
Fig. 2 Pressing tapered roller bearing outer race into transmission housing:
^ Insert tapered section of pressure piece VW 472/1 into outer race.
Fig. 3 Extracting inner race for right tapered roller bearing:
A - Two-arm puller, e.g. Kukko 20/10 or Kukko 44/2
Note: The differential features a recess under the bearing seat for applying the puller -A-.
Fig. 4 Pressing on inner race for right tapered roller bearing:
WARNING: Wear protective gloves.
- Heat inner race to approximately 100°C, mount and press into place.
Fig. 5 Extracting inner race for left tapered roller bearing:
A - Two-arm puller, e.g. Kukko 204/2
Note: The differential features a recess under the bearing seat for applying the puller -A-.
Fig. 6 Mounting inner race for left tapered roller bearing:
WARNING: Wear protective gloves.
- Heat inner race to approximately 100°C, mount and press into place.
Fig. 7 Driving outer race of left tapered roller bearing out of cover:
- Screw out webs -A- and -B- until they are positioned on outer race inside recess in housing.
- Check shims for damage after removal.
Fig. 8 Driving outer race of left tapered roller bearing into cover:
- Press outer race of left tapered roller bearing into cover using pressure piece 2050.
- Insert tapered section of pressure piece 2050 into outer race.
Fig. 9 Driving ring gear out of housing:
Fig.10 Heating ring gear to approximately 100 Degree C and installing:
WARNING: Wear protective gloves.
- Use locating pins -A- (self-made) to guide ring gear when installing.
- Allow to cool somewhat before screwing in bolts. Then tighten to torque.
Fig. 11 Installing bevel gears:
- Lubricate one-piece thrust washer with gear oil and insert.
- Insert large bevel gears.
- Insert small bevel gears offset by 180° and swivel into place -arrow-.
- Drive bevel gear shaft into final position and secure.
Fig. 12 Removing and installing spring pin:
Removing
- Extract spring pin with circumferential groove using side-cutting pliers.
- Knock out spring pin without circumferential groove from behind with mandrel.
Installing
- Drive in spring pin as far as it will go.