Differential, Disassembling and Assembling

Differential, disassembling and assembling





Special tools and equipment
^ VW 353 Transmission support
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 408 A Press tool
^ VW 412 Press tool





Special tools and equipment
^ 40-105 Thrust plate
^ 3005 Press disk
^ 3259 Tube
^ 3296 Tube
^ 3345 Tube
^ V.A.G. 1332 Torque wrench or equivalent





Special tools and equipment
^ V.A.G 1582 Tapered roller bearing puller
^ V.A.G. 1582/6 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
4- Final drive gear
^ Riveted in production
^ Pressing off, Refer to Fig. 8
^ Installation position: machined side faces toward bolting surface of differential housing
^ Heat to 100°C before installing
^ Fit to differential housing
^ Bolted, Refer to Fig. 10
5- Backing plate
6- Nut, 40 Nm and turn 45° further
7- Clutch housing
8- Shim
^ For differential
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
^ Attaching final drive gear with bolts, Refer to Fig. 10
12- Tapered roller bearing inner race
^ Pulling off, Refer to Fig 3
^ Pressing on, 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
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
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
^ Ensures 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
23- Differential bevel gear shaft
^ Knock out with drift
^ Installing, Refer to Fig. 12
24- Spring pin
^ For securing differential bevel gear shaft
^ Removing and installing - Fig. 11
25- Small differential bevel gear
^ Installing, Refer to Fig. 12
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
29- Oil seal





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° a part) 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.