5 & 6 Speed M/T 02M
Differential, disassembling and assembling
Special tools and equipment
^ VW353 Transmission support
^ VW401 Thrust plate
^ VW402 Thrust plate
^ VW407 Press tool
^ VW408 A Press tool
^ VW412 Press tool
Special tools and equipment
^ 40-105 Thrust plate
^ 3005 Press disk
^ 3259 Tube
^ 3296 Tube
^ 3345 Tube
^ VAG 1332 Torque wrench or equivalent
Special tools and equipment
^ VAG1582 Tapered roller bearing puller
^ VAG1582/6 Grip
^ 1 - Kukko 21/7 Internal puller
^ 4 - Kukko 22/2 Counter support
Note:
^ 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, differential housing, transmission housing or clutch housing are replaced, adjust differential
1 - Transmission housing
2 - Bolt
3 - Differential cage
^ Bolt to final drive gear, Refer to Fig 10
^ Use Parts Supplier to check correct application
4 - Final drive gear
^ Riveted in production
^ Pressing of, Refer to Fig 8
^ Installation position: machined side faces toward bolting surface of differential housing
^ Heat to 100°C before installing
^ Install to differential housing, Refer to Fig. 9
^ Bolted, Refer to Fig. 10
5 - Backing plate
6 - Nut, 40 Nm and turn 45° further
7 - Clutch housing
^ Always replace
8 - Shim
9 - Tapered roller bearing outer race
^ Pulling out, Refer to Fig. 5
^ Pressing in, Refer to Fig. 6
10 - Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 4
11 - Differential housing
^ With riveted final drive gear
^ When replacing final drive gear drill out rivet heads, Refer to Fig. 7
^ Attaching final drive gear with bolts, Refer to Fig. 10
12 - Tapered roller bearing inner race
^ Pulling of, Refer to Fig 3
^ - Pressing, Refer to Fig 4
13 - Tapered roller bearing outer race
^ Pulling out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
14 - Shim
^ Always 0.65 mm thick
15 - Oil seal
^ For right-hand flanged shaft
^ Left and right-hand diameters differ.
^ Use Parts Supplier to check correct application
16 - Counter-sunk head bolt, 25 Nm
^ Bolt into threaded piece (item - 26 -)
17 - Left-hand flange shaft
^ Do not interchange, left and right-hand flange shafts differ
^ Use Parts Supplier to check correct application
18 - Spring for flanged shaft
^ Installed behind flanged shafts
19 - Thrust washer
^ Installation position: shoulder toward spring, tongue to tapered ring
20 - Tapered ring
^ With grooves to secure thrust washer
^ Installation position: Taper toward differential housing
21 - Securing clip
^ Make sure that taper ring, thrust washer and spring are held in position when flange shaft is removed
22 - Large differential bevel gear
^ Installing, Refer to Fig. 12
^ Use Parts Supplier to check correct application
23 - Differential bevel gear shaft
^ Knock out with drift
^ Installing, Refer to Fig. 12
^ Use Parts Supplier to check correct application
24 - Spring pin
^ For securing differential bevel gear shaft
^ Use Parts Supplier to check correct application
^ Removing and installing, Refer to Fig. 11
25 - Small differential bevel gear
^ Installing, Refer to Fig. 12
^ Use Parts Supplier to check correct application
26 - Threaded piece
^ Installing, Refer to Fig. 12
27 - One-piece thrust washer
^ Coat with transmission oil when installing
28 - Left-hand flanged shaft
^ Do not interchange, left and right-hand flange shafts differ
^ Use Parts Supplier to check correct application
29 - Oil seal
^ For left-hand flanged shaft
^ Left and right-hand diameters differ.
Fig. 1 Pulling tapered roller bearing outer race out of clutch housing
A - Counter support, e g Kukko 22/2
B - Internal puller 46 to 58 mm, e g. Kukko 21/7
Note: After pressing out, check washer for damage and replace if necessary.
Fig. 2 Pressing tapered roller bearing outer race into clutch housing
^ First insert washer.
Fig. 3 Pulling off tapered roller bearing inner race
^ Before mounting extractor position press piece 40-105 on differential housing.
Note: Both tapered roller bearing inner races are pulled off the differential housing in the same way.
Fig. 4 Pressing on tapered roller bearing inner race
Note: The tapered roller bearing inner races for transmission housing and clutch housing are pressed on with the same press tools.
Fig. 5 Pulling tapered roller bearing outer race out of transmission housing
A - Counter support, e g Kukko 22/2
B - Internal puller 46 to 58 mm, e g. Kukko 21/7
Fig. 6 Pressing tapered roller bearing outer race into transmission housing
^ Support transmission housing with tube 3345 directly below bearing mounting.
Fig. 7 Drilling out rivet heads
^ Drill out rivet heads with 12 mm drill from countersunk side and drive rivet out with drift.
Note: Clean differential before and after drilling, protect tapered roller bearing from metal particles.
Fig. 8 Pressing off final drive gear
^ Place thrust piece 40-105 on differential housing.
Fig. 9 Heating final drive gear to approximately 100°C and installing
^ Use bolts -A- from repair kit to guide final drive gear into position during installation.
Fig. 10 Bolting final drive gear -A- and differential housing -B- together
Use special bolts -1- with backing plates -2- and nuts -3- according to Parts Supplier.
Fig. 11 Removing and installing differential bevel gear shaft spring pin
Removing
^ Cover tapered roller bearing inner race to avoid possible damage and ingress of metal particles.
^ Knock out spring pin with chisel, inserting chisel into circumferential groove.
Installing
^ Knock fully into differential cage.
Fig. 12 Installing differential bevel gears
^ Lubricate one piece thrust washer with transmission oil and install.
^ Install both large differential bevel gears and secure (e.g. with flanged shaft).
^ Insert small differential bevel gears (180° apart) and pivot into position.
^ Push differential bevel gear shaft (arrow -A-) in until first small bevel gear.
^ Position threaded pieces (arrow -B-) in large bevel gears.
Installation position: shoulder to bevel gear
^ Drive differential bevel gear shaft into final position and secure with spring pin.