Disassembling and Assembling
Final drive, repair overview
1 Planetary gear
^ Disassembling and assembling.
2 Input gear
^ Removing and installing.
^ Adjusting.
^ Adjusting final drive (overview).
^ Repairs on the input gear can only be performed after components of the planetary transmission have been removed.
3 Drive pinion
^ Removing and installing.
^ Adjusting.
^ Adjusting final drive (overview).
4 Differential
^ Removing and installing.
^ Disassembling and assembling.
^ Adjusting.
^ Adjusting final drive (overview).
Input gear, removing and installing
Required special tools and equipment:
^ VW 402 Press plate
^ VW 407 Press tool
^ VW 771 Multi-purpose tool
^ 30-205 Thrust plate
^ 40-21 Press tool
^ 40-105 Thrust plate
^ V.A.G 1582 Taper roller bearing puller
^ V.A.G 1582/3 Grip
^ V.A.G 1576 Torque wrench or similar
Note:
Drive pinion and differential do riot need to be removed,
Measure friction torque at drive pinion nut before removing input gear.
1 Socket head fastener, 250 Nm (184 ft. lbs.)
^ Engage parking lock to remove and install
^ Use 22 mm socket
^ Before installing socket head fastener, insert axial needle bearing (item 7)
2 Dished washer
^ Curved side faces socket head fastener
3 Shim
^ Determining thickness
4 Taper roller bearing inner race After measuring thickness of shim, install on input gear with locking fluid AMV 185 101 A1 refer to Fig. 3
5 Taper roller bearing outer race
^ Drive out with drift
^ Drive in with 30-205
^ Insert with locking fluid AMV 185 101 A1
6 Transmission housing
7 Axial needle bearing
^ Install with flat side facing input gear
^ Insert into input gear before installing socket head fastener (item 1)
8 Taper roller bearing outer race
^ Drive out with drift
^ Drive in with 30-205 and long enough drift
^ Insert with locking fluid AMV 185 101 A1
9 Taper roller bearing inner race
^ Pulling off refer to Fig. 1
^ Pressing on refer to Fig. 2
^ Insert with locking fluid AMV 185 101 A1 refer to Fig. 3
10 input gear
^ With impulse wheel for Vehicle Speed Sensor (VSS) -G68-
^ Number of teeth.
^ Adjusting.
^ If input gear is damaged, always replace input gear and output gear together
^ Removing refer to Fig. 4
^ If you replace input gear, adjust planet carrier.
Fig. 1 Taper roller bearing inner race, removing
^ Place thrust plate 40-105 on input gear.
Fig. 2 Taper roller bearing inner race. installing
CAUTION!
Place a press piece below the hub of the input gear to avoid damaging the input gear.
Fig. 3 Taper roller bearing inner race, inserting
^ Insert taper roller bearing inner race -arrow- with AMV 185 101 A1
Fig. 4 Input gear, removing
^ Insert socket head fastener without dished washer, shim and axle needle bearing far enough until you have a gap a = 3 mm between socket head fastener and taper roller bearing inner race.
^ Drive out input gear with VW 771 to stop of taper roller bearing inner race.
^ Remove VW 771 and take out input gear.
Drive pinion, removing and installing
Required special tools and equipment:
^ VW 295 Drift
^ VW 402 Press plate
^ VW 408 A Press tool
^ VW 432 Press piece
^ VW 447 i Thrust plate
^ VW 454 Press piece
^ VW 510 Press piece
^ VW 516 Tube
^ 30-204 Installing ring
^ 30-555 Thrust piece
^ 32-109 Tube
^ 40-203/ 1 Split tube
^ 3155 Ring nut wrench
^ 3183 A Castellated box wrench
^ 3274 Adapter
^ V.A.G 1582 Taper roller bearing puller
^ V.A.G 1582/4 Clamping ring
^ Kukko 20-10 Puller
^ V/172 Removal hook
Note:
To remove the drive pinion, remove the selector shaft after taking out the parking lock.
1 Drive pinion
^ Number of teeth.
^ Adjusting
^ Removing refer to Fig. 8
2 Transmission housing
3 Screw, 12 Nm (9 ft. lbs.)
^ Remove screw before removing or installing bearing support ring -item3-.
^ Insert with sealing compound AKD 456 000 01
4 Nut, 250 Nm (184 ft. lbs.)
^ Engage parking lock to remove or install
^ Secure with drift
5 Output gear
^ Number of teeth
^ Pulling off refer to Fig. 1
^ If there are signs of damage, always replace input gear and output gear together
6 Taper roller bearing inner race
^ Pulling off refer to Fig. 2
^ Pressing on refer to Fig. 3
7 Taper roller bearing outer race
^ Drive out with drift
^ Pressing in refer to Fig. 4
8 ATF oil deflector
^ Install together with bearing cap (item 10)
9 Bolt, 25 Nm (18 ft. lbs.)
10 Bearing cap
11 Shim
^ Determining thickness.
12 Parking lock gear
^ Rounded side faces teeth of drive pinion
13 Bearing support ring, 200 Nm (148 ft. lbs.)
^ Remove screw -item 3- before removing or installing bearing support ring.
^ Removing or installing refer to Fig. 5
^ Bearing support ring cannot be unscrewed until selector shaft has been removed
^ Insert bearing supporting ring carefully. Sealing lip and spring must not be damaged.
^ Support ring with seal refer to Fig. 6
14 O-ring
^ Always replace
^ Place onto bearing supporting ring -item 13-
15 Oil seal for drive pinion
^ Remove with screwdriver
^ Installation position refer to Fig. 6
^ Driving in refer to Fig. 7
16 Taper roller bearing outer race
^ Driving in refer to Fig. 9
17 Taper roller bearing inner race
^ Drive off with drift
^ Pressing on refer to Fig. 10
Fig. 1 Output gear, removing
^ -A- Kukko 20-10 and Matra V 172 puller hooks or similar.
Fig. 2 Taper roller bearing inner race, removing
^ Place press piece on collar of output gear.
Fig. 3 Taper roller bearing inner race, installing
Fig. 4 Taper roller bearing outer race, pressing in
Fig. 5 Bearing support ring, removing and installing
Remove locking bolt.
-A- Torque wrench
^ Tighten bearing support ring to 200 Nm (148 ft. lbs.) and secure with locking screw. insert screw with AKD 456 000 01.
Fig. 6 position of seal:
Open side -arrow- faces taper roller bearing outer race
Fig. 7 Drive pinion oil seal, installing
^ Insert oil seal with sealing lip facing special tool 30-204.
Fig. 8 Drive pinion, removing
-A- Closed wrench 32 mm
Fig. 9 Taper roller bearing outer race, installing
^ Insert drive pinion with taper roller bearing inner race, then drive in outer race.
Fig. 10 Taper roller bearing inner race, pressing on
Differential, removing and installing
Required special tools and equipment:
^ VW 681 Oil seal extractor
^ 3155 Ring nut wrench
^ 3301 Spindle with nut from assembly tool
^ 3319 Thrust piece
^ V.A.G 1332 Torque wrench or similar
^ Kukko 18/0 Puller
^ 2 Bolts M8 x 35 mm
^ Washers 8 mm
Note:
^ If you plan to use taper roller bearings again, mark adjusting ring refer to Fig. 2
^ The drive pinion does not need to be removed for removing and installing the differential.
1 Transmission housing
2 Speedometer drive
^ With marking for oil level indication refer to Fig. 4
3 Output shaft/drive flange
^ Install thread facing drive flange
^ Remove before taking out differential
^ First adjust differential before installing
4 O-ring
^ Always replace
5 Adjusting ring
^ Removing refer to Fig. 3
^ If you plan to use bearings again, mark installation position and position on marking again when installing refer to Fig. 2
^ If you install new bearings, follow adjusting instructions
6 Oil seal for drive flange
^ Before installing, pack space between sealing lips with multi-purpose grease
^ Oil seal can be replaced with transmission installed
^ Remove with VW 681
^ Driving in refer to Fig. 1
7 Taper ring
^ Shoulder faces thrust washer
8 Thrust washer
^ Place over compression spring
9 Compression spring
10 Drive flange
^ Insert with taper ring, thrust washer and compression spring
^ Remove before taking out inner circlip on bevel gear
^ Removing and installing refer to Fig. 8
11 Dished washer
12 Circlip
^ Removing and installing refer to Fig. 7
13 Cover
14 Locking element
15 Screw, 12 Nm (9 ft. lbs.)
16 Cover
17 Circlip
^ Removing and installing refer to Fig. 7
18 Dished washer
19 Drive flange
^ Insert with taper ring, thrust washer and compression spring
^ Remove before taking out inner circlip on bevel gear
^ Removing and installing refer to Fig. 8
20 Compression spring
21 Thrust washer
^ Place over compression spring
22 Taper ring
^ Shoulder faces thrust washer
23 Oil seal for drive flange
^ Before installing, pack space between sealing lips with multi-purpose grease
^ Oil seal can be replaced with transmission installed Remove with VW 681 Driving in refer to Fig. 1
24 Bearing body, 150 Nm
^ When installing new bearing, follow adjusting instructions
^ Remove with 3155
^ Installing refer to Fig. 5
25 O-ring Always replace
26 Output shaft/drive flange
^ Install thread facing drive flange
^ Before removing, take out differential
^ First adjust differential before installing
27 Differential
^ Disassembling and assembling
^ Before removing differential, take out bearing body, adjusting ring and output shafts
28 Screw, 12 Nm (9 ft. lbs.)
29 Locking element
Note:
After adjusting taper roller bearings, secure bearing body and adjusting ring.
30 Circlip
^ First remove drive flange before removing circlip
^ Removing and installing refer to Fig, 6
31 Circlip
^ First remove drive flange before removing circlip
^ Removing and installing refer to Fig. 6
32 Seal
^ Always replace
33 Cover
^ For differential
34 Screw, 28 Nm (21 ft. lbs.)
^ Insert with locking compound AMV 185 101 A1
Fig. 1 Drive in flange oil seal to stop
Fig. 2 Adjusting ring, marking
^ If you plan to re-install used bearings, mark installation position -arrow- and align with markings when installing.
Fig. 3 Adjusting ring, removing
Fig. 4 Speedometer drive
^ With transmission installed, check gear oil in final drive.
Fig. 5 Insert differential and screw in bearing body to stop and tighten to 150 Nm (111 ft. lbs.)
Fig. 6 Circlip -arrow-, installing
^ Remove circlip with two screwdrivers.
Fig.7 Circlip for axle flange, removing and installing
^ Remove spindle from bridge -A- of puller Kukko 18-0.
^ Replace spindle with spindle and nut of assembly tool 3301.
^ Install puller Kukko 18-0 to flange, using two 8x35 mm bolts and 8 mm washers.
^ Remove circlip -arrow- for axle flange.
Fig 8 Drive flange, removing and installing
Removing:
^ Install puller Kukko 18-0 to flange, using two 8 x 35 mm bolts and 8 mm washers.
^ Pull off drive flange.
Installing:
^ Attach puller 18-0 to axle flange.
^ Replace spindle -B- of Kukko 18-0 with spindle and nut of assembly tool 3301 refer to Fig. 7.
^ Install drive flange with 3109.
Note:
Drive flange can also be pulled in with VW 39 1,
Differential, Disassembling and assembling
Required 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
^ V.A.G 1582 Taper roller bearing puller
^ V.A.G 1582/3 Clamping ring
^ 30-555 Thrust piece
Note:
^ Heat taper roller bearing inner race to 100 °C (212°F) before pressing on.
^ Heat adjusting ring for taper roller bearing to 100 °C (212°F) before pressing in taper roller bearing outer race.
1 Differential housing with riveted gear for final drive
^ Final drive gear is riveted to 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 Taper roller bearing inner race
^ Pulling off refer to Fig. 1
^ Pressing on refer to Fig. 2
4 Taper 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 taper roller bearing
^ Removing and installing
6 O-ring
^ Always replace
7 O-ring
^ Always replace
8 Adjusting ring for taper roller bearing
^ Removing and installing
9 Output shaft/drive flange
^ Removing and installing
10 Taper roller bearing outer race
^ Remove and install only when adjusting ring is heated
^ Drive out with drift
^ Pressing in refer to Fig. 4
11 Taper roller bearing inner race
^ Pulling off refer to Fig. 1
^ Pressing on refer to Fig. 2
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 into differential housing before inserting 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 the compression spring is pre-tensioned.
18 Shaft for bevel gears
^ Drive out with drift
^ When driving in, be careful not to damage one-piece thrust washer
19 Spring pin
^ To secure shaft for bevel gears
^ Removing and installing refer to Fig. 5
Fig. 1 Taper roller bearing inner race, removing
^ Place press piece 30-555 on differential housing.
Fig. 2 Taper roller bearing inner race, installing
Fig. 3 Differential bevel gears, installing
^ Insert one-piece thrust washer with gear oil.
^ Insert small bevel gears, drive in shaft and secure with spring pin.
^ Insert large bevel gears offset by 180° and move it in direction of arrow.
Fig. 4 taper roller bearing outer race, pressing in
^ With adjusting ring or bearing body heated, insert outer race and press in to stop.
Fig. 5 Planet wheel axle shaft spring pin, removing and installing
^ Length of spring pin 28.5 mm
Removing:
^ Pull out spring pin with side cutter.
Installing:
^ Drive in spring pin to stop.