Differential, Disassembling and Assembling

Special Tools And Equipment
^ VW 402 Press plate
^ VW 408 A Press tool
^ VW 411 Press tool
^ 30-205 Thrust plate
^ 40-21 Press tool
^ VAG 1582 Tapered roller bearing puller





^ VAG 1582/3 Clamping ring





^ 30-555 Thrust piece

Note:
^ Before installing final drive measure friction torque at axle shaft.
^ Heat tapered roller bearing inner race to 100°C (212°F) before pressing on.
^ Heat adjusting ring for tapered roller bearing to 100°C (212°F) before pressing in tapered roller bearing outer race.





1. Differential housing with riveted gear for final drive
^ Final drive gear is riveted onto differential housing and then machined
^ If differential or final drive gear is damaged, replace differential housing together with riveted final drive gear
^ Number of teeth on final drive gear.
2. Output shaft/drive flange
^ Removing and installing.
3. Tapered roller bearing inner race
^ Pulling off refer to Fig. 1
^ Pressing on refer to Fig. 2
^ When replacing note transmission build date.
4. Tapered roller bearing outer race
^ Remove and install only when adjusting ring is heated
^ Drive out with drift
^ Pressing in refer to Fig. 4
5. Bearing body for tapered roller bearing
^ Removing and installing.
6. O-ring
^ Always replace
7. O-ring
^ Always replace
8. Adjusting ring for tapered roller bearing Removing and installing.
9. Output shaft/drive flange
^ Removing and installing.
10. Tapered roller bearing outer race
^ Remove and install only when adjusting ring is heated
^ Drive out with drift
^ Pressing in refer to Fig. 4
11. Tapered roller bearing inner race
^ Pulling off refer to Fig. 1
^ Pressing on refer to Fig. 2
^ Installing refer to Fig. 3
^ When replacing note transmission build date.
12. Driver bushing
^ Drive off together with speedometer drive gear -item 13-
^ Drive on with drift
13. Speedometer drive gear
^ Drive out with a drift
^ Install together with driver bushing -item 12-
14. One-piece thrust washer
^ Place in differential housing before stalling bevel gears
15. Small bevel gears
^ Inserting refer to Fig. 3
16. Large bevel gears
^ Inserting refer to Fig. 3
17. Circlip

Caution!
^ Do not remove circlip before pulling off drive flange, as compression spring is pre-loaded.

18. Shaft for bevel gears
^ Drive out with a drift
^ When driving in, take care not to damage one-piece thrust washer
19. Spring pin
^ For securing bevel gear shaft
^ Removing and installing refer to Fig. 5





Fig. 1 Tapered roller bearing inner race, removing (pulling off)
- Place press piece 30-555 on differential housing.





Fig. 2 Tapered roller bearing inner race, installing (pressing on)

Note:
^ When replacing tapered roller bearing note transmission build date.





Fig. 3 Differential bevel gears, installing
- Install one-piece thrust washer with gear oil.
- Install small bevel gears, drive in shaft and secure with spring pin.
- Install large bevel gears offset 180° and swivel in direction of arrow.





Fig. 4 Tapered roller bearing outer race, installing (pressing in)
- With adjusting ring or bearing body heated, insert outer race and press home to stop.





Fig. 5 Planet wheel axis shaft spring pin, removing and installing
^ Length of spring pin 28.5 mm (1.12 inch)

Removing
- Remove spring pin with side cutters.

Installing
- Drive in spring pin to stop.