5 Speed Manual 02J
5 Speed Manual 02J
Differential, Disassembling And Assembling
Special Tools
- V.A.G 1582 Puller
- V.A.G 1582/3 Grip
- VW 412 Press tool
- 40-105 Thrust plate
- VW 401 Thrust plate
- VW 402 Thrust plate
- VW 408 A Press tool
- VW 473 Thrust piece
- 30-205 Thrust plate
- 3144 Sleeve
- 2007 Thrust pad
Note:
- Heat tapered roller bearing inner race to 100°C before installing.
- Always replace both tapered roller bearings together as a set.
- If differential housing, Transmission housing or clutch housing,tapered roller bearings are replaced, adjust differential.
1. Transmission housing
2. Bolt
3. Differential cage
- Bolt to final drive clear
4. Final drive gear
- Riveted in production
- Paired with output shaft, only replace as a set
- Pressing off refer to Fig. 9
- Installation position refer to Fig. 10
- Heat to 100°C (212°F) before installing
- Mount to differential housing refer to Fig. 11
- Bolting together refer to Fig. 12
5. Packing plate
6. Nut, 70 Nm
7. Shim
- For differential
- Determining thickness.
8. Tapered roller bearing outer race
- Pulling out refer to Fig. 5
- Pressing in refer to Fig. 6
9. Tapered roller bearing inner race
- Pulling off refer to Fig. 3
- Pressing on refer to Fig. 4
10. Differential housing
- With riveted final drive gear
- When replacing final drive gear drill out rivet heads refer to Fig. 8
- Attaching final drive gear with bolts refer to Fig. 11
11. Speedometer drive wheel
- Install on differential housing before pressing on inner race
12. Tapered roller bearing inner race
- Pulling off refer to Fig. 3
- Pressing on refer to Fig. 4
13. Tapered roller bearing outer race
- Driving out refer to Fig. 1
- Pressing in refer to Fig. 2
14. Clutch housing
15. Sleeve
- Installed in conjunction with springs behind flange shafts
- To accept oil seal (item 16)
- Removing and installing.
16. Oil seal
- replacing.
17. Counter-sunk head bolt, 25 Nm
- Bolt into threaded piece (item 25)
18. Flange shaft Removing and installing.
19. Spring for flange shaft
- Installed behind flange shafts
20. Thrust washer
- Installation position: shoulder toward spring, torque toward tapered ring
21. Tapered ring
- With grooves to secure thrust washer
- Installation position: taper toward differential housing
22. Circlip
- Ensures tapered ring, thrust washer and spring are held in position when flange shaft is removed
23. One-piece thrust washer
- Coat with gear oil when installing
24. Differential side gear
- Installing refer to Fig. 14
25. Threaded piece
- Installing refer to Fig. 14
26. Differential pinion shaft
- Drive out with drift
- Installing refer to Fig. 14
27. Spring pin
- For securing differential pinion shaft
- Removing and installing refer to Fig. 13
28. Differential pinion gear
- Installing refer to Fig. 14
29. Differential side gear
- Installing refer to Fig. 14
Fig. 1 Driving tapered roller bearing outer race out of clutch housing
- Remove flange shaft seal mounting sleeve on transmissions with springs behind flange shaft.
Fig. 2 Pressing taper roller bearing outer race into clutch housing
No shim is installed in the clutch housing end.
Fig. 3 Pulling off tapered roller bearing inner race
- Position press piece 40-105 on differential housing.
- Install puller.
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 from transmission housing
A-Counter support, e.g. Kukko 22/2
B-Internal puller 46 - 58 mm, e.g. Kukko 21/7
Fig. 6 Pressing tapered roller bearing outer race into transmission housing
- Install shim under outer race.
- Support transmission housing using sleeve 3144 directly below bearing mounting.
Fig. 7 Both sides of differential housing are chamfered (arrow) to accept tapers rings/springs.
Fig. 8 Drilling out rivet heads
- Drill out river head using 12 mm (1/2 inch) drill from countersunk side and drive out using drift.
Fig. 9 Pressing off final drive gear
- Place thrust piece 40-105 on differential housing.
Fig. 10 Installation position of final drive gear
The circular groove -A- faces toward bolt on side of differential
Fig. 11 Installing final drive gear after heating to approx. 100°C (212°F)
- Use bolts -A-from repair kit to guide final drive gear into position during installation.
Fig. 12 Bolting final drive gear and differential housing together
- Use plates and nuts with special bolts as specified in parts catalog.
Fig. 13 Removing and installing differential pinion shaft spring pin
Removing
- Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and contamination with metal particles.
- Insert chisel into circumferential groove and drive out spring pin.
Installing
- Drive spring pin fully into differential housing.
Fig. 14 Installing differential side gears and pinion gears
- Lubricate one piece thrust washer with gear oil and install.
- Install both side gears and secure (e.g. with flange shaft).
- Turn pinion gears through 180° and pivot into position.
- Push pinion shaft (arrow -A-) in until first pinion gear is contacted.
- Position threaded piece (arrow -B-) in side gears. Installation position: step towards sun wheel.
- Drive pinion shaft into final position and secure with spring pin.