Differential
Differential
Special tools, testers and auxiliary items required
• Thrust plate (VW401)
• Thrust plate (VW402)
• Punch (VW407)
• Thrust disc (VW412)
• Needle bearing drift (VW295)
• Punch (VW408A)
• Thrust pad (VW442)
• Sleeve (40-21)
• Thrust piece (40-105)
• Thrust plate (2050)
• Drift (3138)
• Two-arm puller Kukko 44/2
• Taper roller bearing extractor (VAG1582)
• (VAG1582/6)
• General repair instructions. Refer to => [ Components ] Description and Operation.
• Secure final drive on a repair stand. Refer to => [ Securing Rear Final Drive to Assembly Fixture ] Procedures.
• Replace both taper roller bearings together.
• When replacing the parts marked with *) adjustment work is required => Adjustment overview, refer to => [ Adjustment Overview ] Adjustments.
1 Cover for final drive
2 O-ring
• Replace
• Insert with oil
3 Final drive housing *)
4 Shim "S1"
• Note thickness
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustments.
5 Outer race for small taper roller bearing *)
• Tapping out, refer to => [ Driving small taper roller bearing outer race
out of cover ]
• Pressing in, refer to => [ Pressing in taper roller bearing outer race
small until stop into housing ]
6 Inner race for small taper roller bearing *)
• Pulling off, refer to => [ Pulling off inner race for small taper roller
bearing ]
• Pressing on, refer to => [ Pressing on small taper roller bearing inner
race ]
7 Bolt - 60 Nm + an additional 45° 1/4 turn
• Replace
• Lightly tighten bolts then tighten diagonally to specification.
8 Differential housing *)
9 Ring gear *)
• Paired with pinion shaft (final drive set)
• Allocation based on transmission code letters.
• Drive off housing with a drift, refer to => [ Driving ring gear off housing ]
• Install to differential housing, refer to => [ Installing ring gear ]
10 Spring pin
• For securing shaft for bevel gears
• Drive in flush
11 Inner race for large taper roller bearing *)
• Pulling off, refer to => [ Pulling off inner race for large taper roller
bearing ]
• Pressing on, refer to => [ Pressing on large taper roller bearing inner
race ]
12 Outer race for large taper roller bearing *)
• Tapping out, refer to => [ Driving out outer race for large taper roller
bearing out of cover ]
• Pressing in, refer to => [ Pressing in outer race for large taper roller
bearing into cover ]
13 Shim "S2"
• Note thickness
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustments.
14 Threaded piece
15 Large bevel gear
• Installing, refer to => [ Installing small bevel gears ]
• Adjusting, refer to => [ Adjusting differential bevel gears ]
16 Small bevel gear
• Installing, refer to => [ Installing small bevel gears ]
17 Shaft for planet wheels
• Drive out with drift
18 Adjustment shim
• Redefine thickness, refer to => [ Adjusting differential bevel gears ]
19 Thrust washer
• Check for cracks
Driving small taper roller bearing outer race out of cover
- After removing check shims for damage.
Pressing in taper roller bearing outer race small until stop into housing
Pulling off inner race for small taper roller bearing
A - Two arm puller , e.g. Kukko 44/2
Pressing on small taper roller bearing inner race
CAUTION!
Wear protective gloves!
- Heat inner race to approximately 100 °C, position and push to final position.
Pulling off inner race for large taper roller bearing
- Install thrust plate (40-105) onto differential housing before installing puller.
Pressing on large taper roller bearing inner race
CAUTION!
Wear protective gloves!
- Heat inner race to approximately 100 °C, position and push to final position.
Driving out outer race for large taper roller bearing out of cover
- After removing check shims for damage.
Pressing in outer race for large taper roller bearing into cover
Driving ring gear off housing
Installing ring gear
CAUTION!
Wear protective gloves!
- Locate ring gear guide with centering pins - A - (self-produced) when mounting.
- Heat ring gear to approximately 100 °C and position.
Installing small bevel gears
- If large bevel gears have been replaced, measure and select new shims. Refer to => [ Adjusting differential bevel gears ]
- Insert large bevel gears with re-calibrated shims.
- Insert small bevel gears spaced 180° apart, and then rotate into place - arrow -.
- Insert washers and align.
- Insert threaded pieces.
- Drive small bevel gear shaft into final position and secure.
Adjusting differential bevel gears
- Insert large bevel gears with thinnest shims (0.5 mm).
- Insert small bevel gears at a 180° offset with thrust washers.
• Do not now interchange bevel gears and thrust washers.
- Drive in shaft for bevel gears.
- Press small bevel gears outward.
- Press large bevel gears in direction of - arrow - and check play.
- Ascertain the thickest - just fitting - shim for large bevel gears on each side.
- Select required shims from table.
The following shims are available:
• The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the differential bevel gears - arrow -.
