Differential, Removing and Installing

Special Tools And Equipment
^ VW 391 Puller
^ VW 681 Oil seal extractor
^ 3109 Puller
^ 3155 Ring nut wrench
^ 3319 Thrust piece

Note:
^ Before installing final drive measure friction torque at axle shaft. Final Drive, Overview
^ Axle shaft and overflow reservoir do not need to be removed.
^ If tapered roller bearings are to be reused, mark adjusting ring refer to Fig. 2
^ Drive pinion does not need to be removed for removing and installing differential.





1. Transmission housing
2. Speedometer drive
^ With mark for oil level refer to Fig. 4
3. Output shaft/drive flange
^ Install thread facing drive flange
^ Remove before differential removal
^ Adjust differential before installing
4. O-ring
^ Always replace
5. Adjusting ring
^ Removing refer to Fig. 3
^ If original bearings are re-installed, mark for reinstallation refer to Fig. 2
^ If new bearings are installed, closely follow adjusting instructions.
6. Oil seal for drive flange
^ Before installing, pack space between sealing surfaces with multipurpose grease
^ Can be replaced with transmission installed.
^ Remove with VW 681
^ Installing, (driving in) refer to Fig. 1
7. Tapered ring
^ Shoulder faces thrust washer
8. Thrust washer
^ Place over compression spring
9. Compression spring
10. Drive flange
^ Install with tapered ring, thrust washer and compression spring
^ Remove before removing inner circlip at differential tapered bearing
^ Removing and installing refer to Fig. 7
11. Dished washer
12. Circlip
13. Cover
14. Locking element
15. Bolt
^ 12 Nm (9 ft. lbs.)
16. Cover
17. Circlip
18. Dished washer
19. Drive flange
^ Insert with tapered ring, thrust washer and compression spring
^ Remove before removing inner circlip at differential tapered gear
^ Removing and installing refer to Fig. 7
20. Compression spring
21. Thrust washer
^ Place over compression spring
22. Tapered ring
^ Shoulder faces thrust washer
23. Oil seal for drive flange
^ Before installing, pack space between sealing surfaces with multipurpose grease
^ Can be replaced with transmission installed.
^ Remove with VW 681
^ Installing, (driving in) refer to Fig. 1
24. Bearing body
^ 150 Nm (111 ft. lbs.)
^ When installing new bearing, closely 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 flange, take out differential
^ 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
^ After adjusting tapered roller bearings, secure bearing body and adjusting ring.
30. Circlip
^ Remove drive flange before removing circlip
^ Removing and installing refer to Fig. 6
31. Circlip
^ 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 fluid AMV 185 101 A1





Fig. 1 Drive flange oil seal, installing (drive in to stop)





Fig. 2 Adjusting ring, marking
- Mark installation position (arrow) and align with marks if you plan to reinstall original bearings.





Fig. 3 Adjusting ring, removing





Fig. 4 Speedometer drive
- With transmission installed, check gear oil in final drive.





Fig. 5 Differential, installing
- Insert differential and screw in bearing body to stop and tighten to 150 Nm (111 ft. lbs.)





Fig. 6 Circlip, removing and installing
- When removing circlip (arrow) use two screwdrivers.





Fig. 7 Drive flange, removing and installing

Removing
- Bolt puller Kukko 18-0 to flange using two 8 x 35 mm bolts and 8 mm diameter washers.
- Remove circlip (arrow) for axle flange.
- Remove (pull off) drive flange.

Installing
- Insert drive flange, dished washer, and circlip.





- Pull drive flange in with 3109.

Note:
^ Drive flange can also be pulled in with VW 391.