Differential, Disassembling and Assembling
Differential, disassembling and assembling, 02X, 6-Speed Four-Wheel Drive M/T
Special tools, testers and auxiliary items required
Thrust plate VW401
Thrust plate VW402
Punch VW407
Punch VW408A
Thrust pad VW447H
Thrust pad VW 447 i
Special tools, testers and auxiliary items required
Needle bearing drift VW 295
Thrust ring VW 470
Sleeve 30 - 14
Thrust plate 2050
Thrust pad 3005
Tube 3296
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1332
Taper roller bearing puller V.A.G 1582
Adapter V.A.G 1582/1
Adapter V.A.G 1582/8
- 1 - Internal puller Kukko 21/8
- 4 - Counter-support Kukko 22/2
Note:
Always replace both tapered roller bearings together.
Adjustment work is required when replacing the parts marked with 1).
1 - Transmission housing
2 - Shim "S2"
Note thickness
3 - Outer race for tapered roller bearing (right-side) 1)
Pulling out
Driving in
4 - Inner race for tapered roller bearing (right-side) 1)
Pulling off
Pressing on
5 - Ring gear 1)
Is paired with pinion shaft (final drive set)
Select correct version according to transmission code letters
Drive off housing using a punch
installing onto differential cage
6 - Differential cage1)
7 - Bolt, 30 Nm plus an additional 90° 1/4 turn
Replace
Lightly tighten bolts then tighten in diagonal sequence to correct torque
8 - Inner race for tapered roller bearing (left-side)1)
Pulling off
Pressing on
9 - Outer race for tapered roller bearing (left-side)1)
Pulling out
Pressing in
10 - Shim "S1"
Note thickness
11 - Cover for final drive 1)
With O-ring
12 - One-piece thrust washer
Lubricate with gear oil before installing
13 - Sun wheel
Installing
14 - Differential pinion pin
Drive out with drift after removing spring pin
15 - Spring pin
For securing differential pinion pin
Drive out from differential cage with drift
Pressing in value: 1.5 mm above differential cage
16 - Planetary pinion
^ Installing
Pulling tapered roller bearing outer race (right-side) out of transmission housing
A - Counter-support, e.g. Kukko 22/2
B - Internal puller 56 to 70 mm, e.g. Kukko 21/8
- After removing, check shims for damage.
Driving outer race for tapered roller bearing (right-side) into transmission housing
Pulling off inner race for tapered roller bearing (right-side)
- Before setting up the puller, place thrust pad VW 447 H on differential cage.
Pressing on tapered roller bearing inner race (left and right)
Note:
Use the same tools for pressing on tapered roller bearing inner race on left side and right side.
CAUTION!
Wear protective gloves.
- Heat inner race to approx. 100° C, install in position and press home.
Pulling off inner race for tapered roller bearing (left-side)
- Before setting up the puller, place thrust pad VW 447 H on differential cage.
Pulling tapered roller bearing outer race (left-side) out of cover for final drive
A - Counter-support, e.g. Kukko 22/2
B - Internal puller 56 to 70 mm, e.g. Kukko 21/8
- After removing, check shims for damage.
Pressing tapered roller bearing outer race (left-side) into cover for final drive.
Driving ring gear off cage
Heating ring gear to approx. 100° C and installing
- When installing ring gear, use centralizing pins - A - (shop-made tool) to locate.
CAUTION!
Wear protective gloves.
- Allow to cool slightly before screwing in new securing bolts. Then tighten to specified torque.
Installing differential bevel gears
- Lubricate one-piece thrust washer with gear oil and install.
- Insert sun wheels.
- Insert planet pinions offset 180° and rotate into position - arrow -.
- Drive differential pinion pin into final position and secure.