Removing and Installing

Differential, removing and installing
Special tools and workshop equipment required





- VW 771 Multipurpose tool
- 3257 Socket, 27 mm AF
- VAG 1331 Torque wrench
- 1 - Kukko 21/3 Internal puller

Note: The differential can be removed and installed when file transmission is installed in the vehicle.





1. Transmission housing
- Casing manufactured from either aluminum or magnesium
- Allocation
2. Oil seal
3. Securing clip
- Removing and installing see Fig. 1
4. Spacer ring
- Is only fitted with drive shafts that have a spline diameter of 30 mm
- Removing see Fig. 2
- Installing see Fig. 3
5. Flange shaft
- - Removing and installing flange shaft assembly see Fig. 4
6. Differential
- Modification: adapted on cover side to enlarged taper roller bearing
7. Cover
- For final drive
- If aluminum (bright), can only be fitted to an aluminum transmission housing
- If magnesium (matt gray), can only be fitted to a magnesium transmission housing
- Identification shortly after standard production see Fig. 5
- Allocation
- Modification: adapted to enlarged taper roller bearing
8. Torx screw
- For aluminum transmissions 36 mm long
- 25 Nm
- For magnesium transmissions 42 mm long
- Always replace
- 25 Nm
- From transmission build date 25.09.7 modified for magnesium transmissions see Fig. 3
9. Speedometer drive wheel





Fig. 1 Removing and installing circlip
- Clamp flange shaft in vice, using vice clamps. Use new circlip -A- to press old circlip out of groove in flange shaft.





Fig. 2 Removing spacer ring
A - Internal extractor, e.g. Kukko 21/3, 18.5 to 23.5 mm
- If the spacer ring is tight pull out using the multi-purpose tool VW 771.





Fig. 3 Installing spacer ring
- Drive new spacer ring in onto stop, when doing this do not cant ring.





Fig. 4 Flange shaft assembly
1. Flange shaft
2. Needle roller bearing (polygon bearing)
3. Spacer ring
4. Spacer ring - additionally installed for spline diameter of 30 mm
5. Circlip
With the flange shaft removed, the needle roller bearing (polygon bearing) moves with difficulty. This is not an indication that the bearing is defective.





Fig. 5 Differential cover identification
On magnesium transmissions Mg Al 9 Zn 1 can be found in the area of the arrow
Mg = Magnesium; additional data is only for production.





Fig. 6 Transmission cover securing bolts modified for magnesium transmissions
From transmission build date 25.09.7 only bolts with a washer are installed in the 4 lower holes (arrows).
The bolts have a length of 51 mm
- In this area no bolts without washers must be installed otherwise the transmission cover below the bolt head contact surface will be damaged due to contact corrosion.