Disassembling and Assembling

Differential, Disassembling And Assembling

Note:
^ Heat taper roller bearing inner race to 100°C (212°F) before installing.
^ Always replace both tapered roller bearings together as a set.
^ If tapered roller bearings, differential housing, final drive cover, ring and pinion or the transmission housing is replaced the differential must be adjusted.





1. Transmission housing
2. Shim S2
^ Note thickness
^ Adjustment overview
3. Tapered roller bearing outer race
^ Driving out - Fig. 1
^ Pressing in - Fig. 2
4. Tapered roller bearing inner race
^ Pulling off - Fig. 3
^ Pressing on - Fig. 4
5. Ring gear
^ Matched to pinion shaft (gear set)
^ Drive off with a drift - Fig. 8
^ Install on differential housing - Fig. 9
6. Differential housing
7. Bolt
^ 60 Nm (44 ft. lbs.) plus 90° turn
^ Always replace
^ First hand-tighten bolts, then tighten evenly in diagonal pattern to correct torque
8. Tapered roller bearing inner race
^ Pulling off - Fig. 5
^ Pressing on - Fig. 4
9. Speedometer drive gear
10. Tapered roller bearing outer race
^ Driving out - Fig. 6
^ Pressing in - Fig. 7
11. Shim S1
^ Note thickness
^ Adjustment overview
12. Cover
13. Large differential gears
^ Installing - Fig. 10
14. Differential bevel gear shaft
^ Drive out with drift after removing spring pin
15. Spring pin
^ For securing differential bevel gear shaft
^ Removing and installing; see Fig.11
16. Small differential gears
^ Installing - Fig. 10
^ Drive out with drift
17. Thrust washer assembly
^ Coat with gear oil when installing






Fig. 1 Driving tapered roller bearing outer race out of housing
- Turn tabs -A- and -B- out until they contact outer race within recess in transmission
- Check shims for damage after removing race






Fig. 2 Pressing tapered roller bearing outer race into housing
- Install tool VW 472/1 with cone in outer race






Fig. 3 Pulling off tapered roller bearing inner race
A- Commercially available two arm puller, e g Kukko 20/10






Fig. 4 Pressing on tapered roller bearing inner race

Note: The tapered roller bearing inner races for the transmission housing and cover are pressed on with the same press tools.






Fig. 5 Pulling off tapered roller bearing inner race
A - Commercially available two arm puller, e.g. Kukko 204/2






Fig. 6 Driving tapered roller bearing outer race out of cover
- Turn tabs -A- and -B- out until they contact outer race within recess in cover.
- Check shims for damage after removing race.






Fig. 7 Pressing tapered roller bearing outer race into cover
- Install tool VW 472/1 with cone in outer race.






Fig. 8 Driving ring gear off differential housing







Fig. 9 Heating ring gear to approx. 100°C (212°F) and installing
- When installing ring gear use guide pins -A- (local manufacture).






Fig. 10 Installing differential gears
- Lubricate thrust washer assembly with gear oil and install.
- Insert large differential gears.
- Install small gears, offset 180°, and pivot into position (arrow).
- Drive bevel gear shaft into final position and secure with spring pin.






Fig. 11 Removing and installing spring pin

Removing
- Pull out spring pin using side cutters.

Installing
- Drive in spring pin as far as stop.