Differential, Disassembling and Assembling

Differential, disassembling and assembling, 01E, 6 Spd. M/T AWD

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

Special tools and workshop equipment required (continued):

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

Special tools and workshop equipment required (continued):

^ V.A.G 1582 Taper roller bearing puller
^ V.A.G 1582/3 Grip piece
^ V.A.G 1582/6 Grip piece





1 - Transmission housing 1)
2 - Shim S2
^ Note thickness
^ Adjustment overview

3 - Taper roller bearing outer race, small 1)
^ Tapping out go to Fig. 9
^ Tapping in go to Fig. 10

4 - Taper roller bearing inner race, small 1)
^ Pulling off go to Fig. 1
^ Pressing on go to Fig. 3

1) 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 Catalog
^ Drive off with a drift go to Fig. 5
^ Fit to differential housing go to Fig. 6

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, large1)
^ Pulling off go to Fig. 2
^ Pressing on go to Fig. 4





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, large1)
^ Tapping out go to Fig. 11
^ Tapping in go to Fig. 12

11 - Shim S1
^ Note thickness
^ Adjustment overview

12 - Cover for final drive 1)
^ With O-ring
^ Replace O-ring
^ Lubricate O-ring before installing





13 - Adjustment shim
^ Redefine thickness go to Fig. 8

14 - Large bevel gear
^ Installing go to Fig. 7
^ Adjusting go to Fig. 8

15 - Threaded piece
16 - Thrust washer
^ Check for cracks and chipping

17 - Small bevel gear
^ Installing go to Fig. 7
^ Adjusting go to Fig. 8

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°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 go to Fig. 8
- 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








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.





Fig. 12 Driving outer race for large taper roller bearing into cover