Differential, Disassembling and Assembling
4 Speed Automatic 01M
Differential, disassembling and assembling
Special tools and equipment
- VW 402 Thrust plate
- VW 408 A Press tool
- VW 411 Press tool
- 30-205 Thrust plate
- 40-21 Press tool
- V.A.G 1582 Tapered roller bearing puller
- VW 191
- VW 472/1 Thrust piece
- VW 472/2 Thrust piece
- VW 792 Thrust piece
- 3347 Assembly tool
- 2010
- VW 433 Thrust piece
- V.A.G 1582/6 Grip
- V.A.G 1582/6A Grip
- V.A.G 1582/11 Grip
- Kukko 21/7 Internal puller
- Kukko 22/2 Counter-support
- V.A.G 1582/3 Clamping ring
- 30-555 Thrust piece
Note:
- Heat tapered roller bearing inner race to 100°C before pressing on.
- Heat adjusting ring for tapered roller bearing to 100°C 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 the differential or final drive gear is damaged, replace the differential housing together with the riveted final drive gear
- Number of teeth on final drive gear
- The differential housings differ depending on the diameter of the tapered roller bearings
2. Output shaft/drive flange
3. Tapered roller bearing inner race
- There are different sizes of tapered roller bearings.
- Pulling off see Fig. 1 and Fig. 3
- Pressing on see Fig. 2 (with equal sized bearings on both sides)
- Pressing on see Fig. 4
4. Tapered roller bearing outer race
- Remove and install only when adjusting ring heated
- Drive out with drift
- Pressing in see Fig. 6
5. Bearing body for tapered roller bearing
- There are different types of bearing body
- Pulling off tapered roller bearing/inner race as Fig. 9
- Pressing on see Fig. 8
- Pressing on see Fig. 10
6. O-ring
- Always replace
7. O-ring
- Always replace
8. Adjusting ring for tapered roller bearing
9. Output shaft/drive flange
10. Tapered roller bearing outer race
- Remove and install only when adjusting ring heated
- Drive out with drift
- Pressing in see Fig. 6
11. Tapered roller bearing inner race
- There are different sizes of tapered roller bearings.
- Pulling off as Fig 1 (with equal sized bearings on both sides)
- Pressing on see Fig. 2
- Inserting see Fig. 5
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
- Fit on together with driver bushing -item 12-
14. One-piece thrust washer
- Place into differential cage before inserting bevel gears
15. Small bevel gears
16. Large bevel gears
- Inserting see Fig 5
17. Circlip
WARNING: Do not remove circlip until after pulling off drive flange as compression spring is pre-tensioned.
18. Shaft for bevel gears
- Drive out with a drift
- When driving in, do not damage one piece thrust washer
19. Spring pin
- For securing shaft for bevel gears
- Removing and installing see Fig. 11
Fig. 1 Pulling off tapered roller bearing inner race
- Use adapter V.A.G 1582/6A for larger bearings
- Place press piece 30-555 on differential housing.
Fig. 2 Pressing on tapered roller bearing inner race
Fig. 3 Pulling out tapered roller bearing outer race
Fig. 4 Pressing in tapered roller bearing outer race
Fig. 5 Inserting differential bevel gears
- 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 180° and swivel in direction of arrow.
Fig. 6 Pressing in tapered roller bearing outer race
- With adjusting ring or bearing body heated, insert outer race and press home as far as stop.
Fig. 7 Pulling out tapered roller bearing outer race
A - Kukko 22/2 counter-support
B - Kukko 21/7 internal puller
Fig. 8 Pressing in tapered roller bearing outer race
Fig. 9 Pulling off tapered roller bearing inner race
- Place press piece VW 433 on bearing body.
Fig. 10 Pressing on tapered roller bearing inner race
Fig. 11 Removing and installing planet wheel axis shaft spring pin
- Length of spring pin 28.5 mm
Removing
- Pull out spring pin with side cutting pliers.
Installing
- Drive in spring pin as far as stop.