Differential
Differential
Special tools, testers and auxiliary items required
• Needle Bearing Drift (VW 295)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Thrust Pad (VW 442)
• Sleeve (40-21)
• Thrust Piece (40-105)
• Thrust Plate (2050)
• Drift (3138)
• Torque Wrench (V.A.G 1332)
• Taper Roller Bearing Puller (V.A.G 1582)
• Collar for Wheel Bearing Inner Race (V.A.G 1582/6)
• Puller (Kukko 44/2)
Warm the inner races/tapered roller bearings to 100° C (212° F) before installing.
Replace both tapered roller bearings at the same time.
The differential must be adjusted whenever the tapered roller bearing, the differential housing, the rear final drive cover, the drive train or the transmission housing is replaced. Refer to => [ Ring Gear, Adjusting ] Pinion and Ring Gear, Adjusting.
Place the rear final drive in the assembly stand
* It is necessary to perform an adjustment if these parts are replaced. Refer to => [ Adjusting Overview ] Pinion and Ring Gear, Adjusting.
1 Rear Final Drive Cover*
2 O-ring
• Always replace
• Install with oil
3 Rear Axle Housing *
4 Shim S1
• Write down the thickness
• For the adjustment overview, refer to => [ Adjusting Overview ] Pinion and Ring Gear, Adjusting
5 Outer Race/Small Tapered Roller Bearing *
• Removing
• Installing
6 Inner Race/Small Tapered Roller Bearing *
• Removing
• Installing
7 Hex Bolt
• Always replace
• 60 Nm and turn additional 45°
• Counterhold the bolts and then tighten them diagonally to the tightening specification.
8 Differential Housing*
9 Ring Gear*
• Is paired with the pinion (drive train)
• Removing using the drift
• Mounting on the differential housing
10 Adapter Sleeve
• For securing the differential bevel gear axle
• Install so that it is flush
11 Inner Race/Large Tapered Roller Bearing *
• Removing
• Installing
12 Large Outer Race/Tapered Roller Bearing *
• Removing
• Installing
13 Shim S2
• Write down the thickness
• For the adjustment overview, refer to => [ Adjusting Overview ] Pinion and Ring Gear, Adjusting
14 Threaded Piece
15 Large Differential Bevel Gear
• Installing
• Adjusting
16 Small Differential Bevel Gear
• Installing
17 Differential Bevel Gear Axle
• Removing using the drift
18 Shim
• Selecting a thickness
19 Thrust Washer
• Check for cracks
Place the Rear Final Drive in the Assembly Stand
Removing the Outer Race/Small Tapered Roller Bearing
- Check the shims for damage after removing them.
Installing the Outer Race/Small Tapered Roller Bearing
Removing the Inner Race/Small Tapered Roller Bearing
A - two-arm puller, commercially available, for example (Kukko 44/2)
Installing the Inner Race/Small Tapered Roller Bearing
CAUTION!
Wear protective gloves.
- Warm the inner race to approximately 100° C (212° F) before installing
Removing the Inner Race/Large Tapered Roller Bearing
- Mount the (40-105) on the differential housing before installing the puller.
Installing the Inner Race/Large Tapered Roller Bearing
CAUTION!
Wear protective gloves.
- Warm the inner race to approximately 100° C (212° F) before installing
Removing the Outer Race/Tapered Roller Bearing from the Cover
- Check the shims for damage after removing them.
Installing the Outer Race/Tapered Roller Bearing into the Cover
Remove the Ring Gear from the Housing
Installing the Ring Gear
CAUTION!
Wear protective gloves.
- Warm the ring gear to approximately 100° C (212° F) and install it.
- Guide the ring gear with centering pins - A - (self-made) when installing it.
Installing the Differential Bevel Gears
- Measure the shims again if the large differential bevel gear was replaced.
- Install the large differential bevel gears with the measured shims.
- Install the differential bevel gears offset 180° - arrow -.
- Install and align the thrust washers.
- Install the threaded pieces. Make sure they fit correctly.
- Install the differential bevel gear axle.
Adjusting the Differential Bevel Gear
- Install the large differential bevel gears with 0.5 mm shims.
- Install the small differential bevel gear offset 180° with thrust washers.
Make Sure not to Interchange the Thrust Washers.
- Install the differential bevel gear axle.
- Push the small differential bevel gear toward the outside.
- Push the large differential bevel gear in direction of - arrow - and check the play.
- Determine the thickest shim that can still be inserted on each side of the large differential bevel gears.
- Select shims with the same thickness.
Shim Table
The adjustment is correct if there is no play and yet it is still possible to turn the differential bevel gears.
