Differential, Disassembling and Assembling
Differential, Disassembling and Assembling - 6 Spd. Manual Transmission 0A3 All Wheel Drive
Special tools, testers and auxiliary items required
^ Drift VW 295
^ Pressure plate VW 401
^ Pressure plate VW 402
^ Punch VW 408 A
^ Punch VW 411
^ Punch VW 412
Special tools, testers and auxiliary items required
^ Thrust pad VW 447 H
^ Thrust shell for drive pinion bearing VW 470
^ Sleeve 30 - 14
^ Press tube 30 - 23
^ Sleeve 40 - 103
^ Thrust piece 2050
Special tools, testers and auxiliary items required
^ Taper roller bearing puller V.A.G 1582
^ Attachment V.A.G 1582/1
^ - 1 - Internal extractor Kukko 21/8
^ - 4 - Support Kukko 22/2
Differential, removing and installing.
Note:
^ Always replace both taper roller bearings together as a set.
^ Adjustments are required when replacing components marked with 1).
1 - Transmission housing 1)
2 - Adjustment shim "S2"
^ Note thickness
^ Adjustment overview
3 - Outer race for right tapered roller bearing 1)
^ Pulling out
^ Driving in
4 - Inner race for right tapered roller bearing 1)
^ Pulling off
^ Pressing on
5 - Ring gear 1)
^ Mated with drive pinion (final drive set)
^ Allocate according to transmission code
^ Press off of housing using drift
^ Install on differential housing
6 - Differential housing 1)
7 - Bolt, 60 Nm plus an additional 45 degree turn
^ Always replace
^ Lightly fasten bolts, then tighten in a diagonal sequence to torque specification
8 - Inner race for left tapered roller bearing 1)
^ Pulling off
^ Pressing on
9 - Outer race for left tapered roller bearing 1)
^ Pulling out
^ Pressing in
10 - Adjustment shim "S1"
^ Note thickness
^ Adjustment overview
11 - Final drive cover 1)
^ With O-ring
12 - Thrust washer union
^ Install coated with gear oil
13 - Large differential bevel gear
14 - Axle for differential bevel gears
^ Drive out with drift after removing spring pin
15 - Roll pin
^ For securing axle for differential bevel gears
^ Sheared off at removal
^ Drive in flush
16 - Small differential bevel gear
Pulling outer race for right tapered roller bearing out of transmission housing
A - Support, e.g. Kukko 22/2
B - Internal puller 56 to 70 mm, e.g. Kukko 21/8
- After removing, check shims for damage.
Right tapered roller bearing outer race, driving into transmission housing
Tapered roller bearing inner races, removing
- Before installing puller, set thrust pad VW 447 H onto differential housing.
Note:
^ Removing differential left and right tapered roller bearing inner race is identical.
Pressing off left and right tapered roller bearing inner race
Note:
^ Left and right tapered roller bearing inner races are pressed off with the same tools.
CAUTION!
Wear protective gloves!
- Heat inner race to approx. 100 degree C, fit in position and press in.
Left tapered roller bearing outer race, removing from final drive cover
A - Support, e.g. Kukko 22/2
B - Internal puller 56 to 70 mm, e.g. Kukko 21/8
- After removing, check shims for damage.
Left tapered roller bearing outer race, pressing into final drive cover
Driving ring gear from housing
Heat ring gear to approx. 100 degree C and install
- When installing ring gear, guide with centering pins - A - (self-made).
CAUTION!
Wear protective gloves!
- Before installing new screws, allow to cool off somewhat. Then tighten to specified torque.
Differential planetary gear axle, removing
Spring pin is sheared off when pressing out.
- Drive remaining spring pin parts out of differential housing and differential planetary gear axle.
Differential planetary gears, installing
- Insert thrust washer union with transmission fluid.
- Insert large differential planetary gears.
- Install small differential bevel gears at 180 degree from their final position and rotate into place - arrow -.
- Align holes of thrust washer union, small planetary gears and differential housing.
- Drive axle for differential bevel gears into final position and secure.