Differential: Service and Repair
Differential
Special tools, testers and auxiliary items required
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Thrust Disc (VW 412)
• Press Tube (30 - 23)
• Thrust Piece (40-105)
• Thrust Pad (3005)
• Tube (3259)
• Tube (3296)
• Assembly Tool (3301)
• Press Tool (3345)
• - 1 - Kukko 21/7 internal puller
• - 2 - Kukko 18/1 puller 65-160mm
• - 3 - Separating tool 17/1
• - 4 - Kukko 22/2 counter-support
• - 3 - Kukko puller 204/2
Pulling Outer Race/Tapered Roller Bearing Off Clutch Housing
A Support, for example (Kukko 22/2)
B Internal puller 46 to 58 mm, for example (Kukko 21/7)
- Tension internal puller - B - between the outer ring for the tapered roller bearing and adjustment shim.
• After pulling off, check the adjustment shim for damage and replace if necessary.
Pressing in Outer Race/Tapered Roller Bearing into Clutch Housing
- Insert the adjustment shim beforehand.
• The shoulder on the inner diameter of the (3005) points toward the outer ring.
Pulling Off Inner Race for Tapered Roller Bearing
- Place the (40-105) on the differential housing.
- Tension the puller for example (Kukko 204/2) in the area of the flattened sides of the differential housing below the inner ring.
• When pulling off inner race, make sure that the hooks do not bend outward; if necessary re-tighten bolt - arrow -.
Pressing On Tapered Roller Bearing Inner Race
Pulling Off Inner Race for Tapered Roller Bearing
A Extractor, for example (Kukko 18/1)
B Separating device 12 to 75 mm, for example (Kukko 17/1)
Pressing on Tapered Roller Bearing Inner Race
- Place the sleeve (3301/3) from the (3301) with the notch - arrow - (larger inner diameter) on the inner race for the tapered roller bearing.
Pulling Outer Race/Tapered Roller Bearing Out of Transmission Housing
A Support, for example (Kukko 22/2)
B Internal puller 46 to 58 mm, for example (Kukko 21/7)
Pressing in Tapered Roller Bearing Outer Race Into Transmission Housing
- Support transmission housing directly beneath bearing mount using (3345).
Removing the Differential Bevel Gear Axle and Spring Pin
- First drive roll pin - 1 - flush into differential bevel gear axle - 2 -.
- Place differential with roll pin - arrow - facing toward (30 - 23) below press.
- Then press out differential bevel gear axle.
• Remove sheared of parts of roll pin from differential bevel gear axle if necessary.
Installing the Differential Bevel Gears
- Insert thrust washer union with transmission fluid.
- Insert both large differential bevel gears and secure (for example with flange shaft).
- Insert the small differential planetary gears 180° offset and pivot them into position.
- Press in the differential bevel gear axle - arrow A - up to the first small differential bevel gear.
- Insert threaded pieces - arrows B - in large differential bevel gears.
• Installed position: shoulder faces the differential bevel gear
- Drive differential planetary gear axle into final position and secure with spring pin.
Roll Pin, Installing
- Drive new roll pin - arrow - flush into differential bevel gear axle with a drift - 1 -.
A005TT016-031510