Differential
Differential
Special tools, testers and auxiliary items required
• Thrust plate (VW 401)
• Thrust plate (VW 402)
• Press tool (VW407)
• Press tool (VW412)
• Drift (VW295)
• Press tool (VW408A)
• Press tool (VW442)
• Press tool (40-21)
• Thrust plate (40-105)
• Thrust pad (VAS 2050)
• Drift (3138)
• Two-arm puller Kukko 44/2
• Tapered roller bearing puller (VAG1582)
• Extractor tool (V.A.G 1582/6)
• General repair instructions => [ General Repair Instructions ] Rear Final Drive 01R (09EA Transmission).
• Secure final drive on engine/transmission support => [ Rear Final Drive, Securing to Engine/Transmission Support ] Rear Final Drive, Securing to Engine/Transmission Support.
• Always replace both tapered roller bearings together as a set.
• Adjustments are required when replacing components marked 1) adjustment overview , => [ Adjustment Overview ] Adjustments.
1 Cover for final drive 1)
2 Seal
• Always replace
• Lubricate with oil when installing
3 Final drive housing 1)
4 Shim "S1"
• Note thickness
• Adjustment overview => [ Adjustment Overview ] Adjustments
5 Outer race for small tapered roller bearing 1)
• Driving out => [ Driving outer race of small tapered roller bearing
out of housing ]
• Pressing in => [ Pressing outer race of small tapered roller
bearing into transmission housing as far as it will go ]
6 Inner race for small tapered roller bearing 1)
• Pulling out => [ Pulling off inner race for small tapered roller
bearing ]
• Pressing in => [ Pressing on inner race for small tapered roller
bearing ]
7 Bolt - 60 Nm plus an additional 45° turn
• Always replace
• Allocation:
• Lightly tighten bolts then tighten in diagonal sequence to correct torque
8 Differential housing 1)
9 Ring gear 1)
• Paired with drive pinion (final drive set)
• Select correct version according to code letters:
• Drive off housing with a punch => [ Driving ring gear off housing ]
• Installing on differential housing => [ Installing ring gear ]
10 Roll pin
• For securing differential bevel gear shaft
• Drive in flush
11 Inner race for large tapered roller bearing 1)
• Pulling off => [ Pulling off inner race for large tapered roller
bearing ]
• Pressing on => [ Pressing on inner race for large tapered roller
bearing ]
12 Outer race for large tapered roller bearing 1)
• Driving out => [ Driving outer race for large tapered roller
bearing out of cover ]
• Pressing in => [ Pressing outer race for large tapered roller
bearing into cover ]
13 Shim "S2"
• Note thickness
• Adjustment overview => [ Adjustment Overview ] Adjustments
14 Threaded piece
15 Large differential bevel gear
• Installing => [ Installing small and large differential bevel
gears ]
• Adjusting => [ Adjusting differential bevel gears ]
16 Small differential bevel gear
• Installing => [ Installing small and large differential bevel
gears ]
17 Differential bevel gear shaft
• Drive out with drift
18 Shim
• Re-checking thickness => [ Adjusting differential bevel gears ]
19 Thrust washer
• Check for cracks
Driving outer race of small tapered roller bearing out of housing
- After removing check shims for damage.
Pressing outer race of small tapered roller bearing into transmission housing as far as it will go
Pulling off inner race for small tapered roller bearing
- A -Two-arm puller Kukko 44/2
Pressing on inner race for small tapered roller bearing
CAUTION!
Wear protective gloves.
- Heat bearing to approx. 212° F (100° C), place in position and press home.
Pulling off inner race for large tapered roller bearing
- Before mounting extractor, position press piece (40-105) on differential housing.
Pressing on inner race for large tapered roller bearing
CAUTION!
Wear protective gloves.
- Heat bearing to approx. 212° F (100° C, place in position and press home.
Driving outer race for large tapered roller bearing out of cover
- After removing check shims for damage.
Pressing outer race for large tapered roller bearing into cover
Driving ring gear off housing
Installing ring gear
CAUTION!
Wear protective gloves.
- When installing, use centralizing pins - A - (local manufacture) to guide ring gear.
- Heat ring gear to approx. 212° F (100° C) and install.
Installing small and large differential bevel gears
- If large differential bevel gears have been replaced, measure and select new shims => [ Adjusting differential bevel gears ].
- Insert large differential bevel gears with measured shims.
- Install small differential bevel gears spaced 180° apart, and rotate into position - arrow -.
- Install and align thrust washers.
- Insert threaded pieces.
- Drive differential bevel gear shaft into final position and secure.
Adjusting differential bevel gears
- Insert large differential bevel gears with thinnest shims (0.5 mm).
- Insert small differential bevel gears with thrust washers spaced 180° apart.
• Do not now interchange bevel gears and thrust washers.
- Drive in differential bevel gear shaft.
- Press small bevel gears outward.
- Press large bevel gears in direction indicated - arrows -, and check amount of play.
- Determine thickest shims for the large bevel gears (on each side) which can still just be inserted.
- Identify shims according to table. Part numbers:
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 -.
