Torsen Housing, Disassembling and Assembling

Torsen Housing, Disassembling and Assembling - 6 Spd. Manual Transmission 0A3 All Wheel Drive





Special tools, testers and auxiliary items required

^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 408 A
^ Punch VW 412
^ Thrust plate VW 454
^ Thrust plate VW 554





Special tools, testers and auxiliary items required

^ Punch 2005
^ Thrust plate 2050
^ Seal driver-frt wheel bearing 30 - 100
^ Torque wrench V.A.G 1331
^ Pulling hook T20143
^ Thrust plate T40106
^ Adjustment shim 016 311 391 A
^ Thread locking compound AMV 185 101 A1
^ Sealing grease G 052 128 A1





1 - Flange shaft

^ Press off
^ Pressing in
^ Change: as of serial number 42987 with groove
^ Allocate components.

2 - Screw - 20 Nm plus an additional 90 degree

^ For vibration dampener
^ Qty. 3
^ Self-locking
^ Replace

3 - Vibration dampener

^ Not present on all versions

4 - Seal

^ Installing up to serial number 42986
^ Change: as of serial number with additional dust lip
^ Installing as of serial number 42987

5 - Torsen housing

^ Removing and installing with transmission removed
^ Removing and installing with transmission installed

6 - Ball bearing

^ For flange shaft
^ Pressing out
^ Pressing in

7 - Circlip





Press off flange shaft (torsen housing with vibration dampener)

- Remove circlip before pressing out flange shaft.
- Position torsen housing so that flange shaft does not come in contact with assembly plate when pressing off - arrows -.





Press off flange shaft (torsen housing without vibration dampener)

- Remove circlip before pressing out flange shaft.





Pressing in flange shaft

- Before pressing in flange shaft, tighten damper.

Note:
^ If a sealing ring is installed with additional dust lip, a flange shaft must be installed with a groove.

- Install securing ring.





As of serial number 42987 - Flange shaft with nut - arrow A - and sealing ring with additional dust lip - arrow B -

Note:
^ Sealing ring with additional dust lip - arrow B - must be installed in connection with flange shaft with groove - arrow A -.





Pry off sealing ring





Differentiation of sealing rings

A - Sealing ring - up to serial number 42986 - without additional dust lip - arrow 1 -.

B - Sealing ring - as of serial number 42987 - with additional dust lip - arrow 2 -.





Sealing ring - up to serial number 42986 - installing

A - Shim 016 311 391 A (1.4 mm thick)

B - Seal

- Set shim and seal onto tool as shown.

^ Installation position: Open side of sealing ring faces towards torsen housing.

- Lightly oil new sealing ring on outer circumference.





- Drive on new flange shaft sealing ring to stop, when doing so, do not tilt.
- Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.
- Remove tool and shim.





Sealing ring - as of serial number 42987 - with additional dust lip, installing

^ Installation position: Open side of sealing ring faces towards torsen housing.

- Lightly oil new sealing ring on outer circumference.
- Drive on new flange shaft sealing ring to stop, when doing so, do not tilt.
- Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.





Pressing out ball bearing for flange shaft





Pressing in ball bearing for flange shaft