Disassembling and Assembling
Differential, Disassembling And Assembling
Special tools and equipment
^ VW295 Needle bearing drift
^ VW401 Thrust plate
^ VW402 Thrust plate
^ VW407 Punch
^ VW408 A Punch
^ VW412 Thrust disc
^ VW442 Thrust pad
^ 40-21 Sleeve
^ 40-105 Thrust piece
^ 2050 Thrust plate
^ 3138 Drift
^ VAG1582 Tapered roller bearing puller
^ VAG1331 Torque wrench
^ VAG 1582/6 Attachment
Notes:
^ Heat tapered roller bearing inner race to 100°C before installing.
^ Always replace both tapered roller bearings together as a set.
^ If tapered roller bearings for the differential housing, final drive cover, pinion or the transmission housing are replaced the differential must be adjusted. Testing and Inspection
1. Cover (1)
2. O-ring
^ Always replace
^ Lubricate with oil
3. Final drive housing (1)
4. Shim S1
^ Note thickness
^ Adjustment overview. Testing and Inspection
5. Small tapered roller bearing outer race (1)
^ Driving out; see Fig. 1
^ Pressing in; see Fig. 2
6. Small tapered roller bearing inner raced
^ Pulling off; see Fig. 3
^ Pressing on; see Fig. 4
7. Bolt
^ Always replace
^ 60 Nm (44 ft. lbs.) + 1/8-turn (45°)
^ Lightly tighten bolts then tighten diagonally to correct torque
8. Differential housing (1)
9. Ring gear 1)
^ Matched to pinion (pinion set)
^ Allocate according to transmission code letters using parts catalog microfiche
^ Drive off using drift; see Fig. 9
^ Installing on differential housing; see Fig. 10
10. Roll pin
^ For securing differential bevel gear shaft
^ Drive in flush
11. Large tapered roller bearing inner race (1)
^ Pulling off; see Fig. 5
^ Pressing on; see Fig. 6
12. Large tapered roller bearing outer race (1)
^ Driving out; see Fig. 7
^ Pressing in; see Fig. 8
13. Shim S2
^ Note thickness
^ Adjustment overview. Testing and Inspection
14. Threaded piece
15. Large differential bevel gear
^ Installing; see Fig. 11
^ Adjusting; see below.
16. Small differential bevel gear
^ Installing; see Fig. 11
17. Differential bevel gear shaft
^ Drive out roll pin -10- then drive out using drift
18. Shim
^ Determining thickness
19. Thrust washer
^ Check for cracks
(1) Adjustment work is required if these components are replaced.
Fig. 1 Driving small tapered roller bearing outer race out of final drive housing
- After removing check shims for damage.
Fig. 2 Pressing small tapered roller bearing outer race in up to stop in final drive housing
Fig. 3 Pulling off small tapered roller bearing inner race
A - Commercially available two arm puller, e.g. Kukko 44/2
Fig. 4 Pressing on small tapered roller bearing inner race
- Heat inner race to approx. 100°C before pressing on.
Fig. 5 Pulling off large tapered roller bearing inner race
- Before installing puller position 40-105 thrust piece on differential housing.
Fig. 6 Pressing on large tapered roller bearing inner race
- Heat inner race to approx. 100°C before pressing on.
Fig. 7 Driving tapered roller bearing outer race out of cover
- After removing check shims for damage.
Fig. 8 Pressing tapered roller bearing outer race into cover
Fig. 9 Driving ring gear off differential housing
Fig. 10 Heating ring gear to approx. 100°C and installing
- When installing ring gear, guide on using centering pins -A- (local manufacture).
Fig. 11 Installing large differential bevel gears and small differential bevel gears
^ Shims must be redetermined if large differential bevel gears have been replaced.
- Install large differential bevel gears with redetermined shims.
- Install small differential bevel gears turned through 180� and pivot into position (arrow).
- Install thrust washers and align.
- Install threaded pieces and make sure they are seated correctly.
- Drive small differential bevel gear shaft into final position and secure with roll pin.
Adjusting large differential bevel gears and small differential bevel gears
- Install large differential bevel gears with 0.5 mm thick shims.
- Install small differential bevel gears turned through 180° together with thrust washers.
From this point on, the differential bevel gears must be kept together with their respective thrust washers.
- Drive in differential bevel gear shaft.
- Press small differential bevel gears outward.
- Press large differential bevel gears in direction of arrows and check clearance.
- Determine thickest shim (that can still just be installed) for large differential bevel gear on each side.
- Select shims of same thickness.
Table of shims
Note: If the bearing clearance cannot be measured, but the bevel gears can just still be turned, the adjustment is acceptable.