Differential, Disassembling and Assembling

5 SPD. A/T 01L AWD

Differential, disassembling and assembling
Special tools and equipment








^ VW401 Thrust plate
^ VW402 Thrust plate
^ VW407 Punch
^ VW412 Punch
^ VW295 Needle bearing drift
^ VW408A Punch

^ VW442 Thrust pad
^ 40-21 Sleeve
^ 40-105 Thrust piece
^ 2050 Thrust plate
^ 3138 Drift
^ Kukko W2 Two-arm puller





^ VAG 1582 Taper roller bearing puller





^ VAG 1582/6

Note:
^ General repair notes
^ Secure final drive in assembly fixture.
^ Replace both tapered roller bearings together
^ Adjustments are required when replacing components marked with 1).





1. Cover for final drive 1)
2. O-ring
^ Replace
^ Insert with oil
3. Final drive housing 1)
4. Adjustment shim "S1"
^ Note thickness
^ List of adjustments
5. Tapered roller bearing outer race 1)
^ Driving out; Refer to Fig. 1
^ Pressing in; Refer to Fig. 2
6. Tapered roller bearing Inner race
^ Removing; Refer to Fig. 3
^ Pressing on; Refer to Fig. 4
7. Bolt (60 Nm plus additional 45°)
^ Replace
^ Assignment; Refer to Parts Supplier
^ Lightly tighten bolts then tighten diagonally to correct torque.
8. Differential housing
9. Ring gear 1)
^ Is matched to drive pinion (gear set)
^ Application according to transmission code letters; Refer to Parts Supplier
^ Drive from housing using mandrel; Refer to Fig. 9
^ Install onto differential housing; Refer to Fig. 10
10. Roll pin
^ For securing shaft for differential bevel gears
^ Drive in flush
11. Double tapered roller bearing Inner race
^ Removing; Refer to Fig. 5
^ Pressing on; Refer to Fig. 6
12. Double tapered roller bearing outer race
^ Driving out Fig. 7
^ Pressing in Fig. 8
13. Shim "S2"
^ Note thickness
^ List of adjustments
14. Threaded piece
15. Large differential bevel gear
^ Installing; Refer to Fig. 11
^ Adjusting; Refer to Fig. 12
16. Small differential bevel gear
^ Installing; Refer to Fig. 11
17. Shaft for differential bevel gears
^ Drive out using drift
18. Adjustment shim
^ Re-determining thickness; Refer to Fig. 12
19. Thrust was her
^ Check for cracks

Fig. 1 Driving small tapered roller bearing outer race out of housing:

^ Check adjustment shims for damage after removing.

Fig. 2 Pressing tapered roller bearing outer race Into housing:

Fig. 3 Pulling off tapered roller bearing Inner race:

A - Kukko 44/2 two-arm puller

Fig. 4 Pressing on tapered roller bearing Inner race:

CAUTION: Wear protective gloves.

^ Heat inner race to approximately 100°C, place on and then press on.

Fig. 5 Pulling off double tapered roller bearing Inner race:

^ Before installing, set 40-105 thrust piece onto differential housing.

Fig. 6 Pressing on double tapered roller bearing Inner race:

CAUTION: Wear protective gloves.

^ Heat inner race to approximately 100°C, place on and then press on.

Fig. 7 Driving out large tapered roller bearing outer race from cover:

^ Check adjustment shims for damage after removing.

Fig. 8 Pressing In large tapered roller bearing outer race Into cover:

Fig. 9 Driving out ring gear from housing:

Fig. 10 Installing ring gear:

CAUTION: Wear protective gloves.

^ Guide ring gear with centering pins -A- (local manufacturer) when installing ring gear.
^ Heat inner race to approximately 100° and insert.

Fig. 11 Install differential bevel gears:

^ If the large differential bevel gears were replaced, adjustment shims must be re-determined; Refer to Fig. 12.
^ Insert large differential bevel gears with determined adjustment shims.
^ Install small differential bevel gears at 180° from their final position and rotate into place (arrow).
^ Install thrust washers and locate.
^ Install threaded pieces.
^ Drive in differential bevel gear shaft to final position and secure.

Fig. 12 Differential bevel gears, adjusting:

^ Install large differential bevel gears with the thinnest shims (0.5 mm).
^ Install small differential bevel gears rotated by 180° together with thrust washers.

Note: Do not rearrange differential bevel gears and thrust washers again!

^ Drive in shaft for differential bevel gears.
^ Press small differential bevel gears toward outside.
^ Push large differential bevel gears in direction of arrow and check play.
^ Determine thickest possible shim that can still be inserted for large differential bevel gears on each side.
^ Select adjustment shims of same thickness.
^ Determine adjustment shims according to table. For Part numbers; Refer to Parts Supplier.





Available adjustment shims:





Note: The adjustment is also correct when no more play is present and the differential bevel gears can just barely be rotated.