Rear Differential, Disassembling and Assembling

Rear differential, disassembling and assembling





Special tools and equipment
^ VW 295 Drift
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 408A Press tool
^ VW 412 Press tool





Special tools and equipment
^ VW 442 Press piece
^ 40-21 Press tool
^ 40-105 Thrust plate
^ 2050 Thrust piece
^ 3138 Driver
^ VAG 1332 Torque wrench





Special tools and equipment
^ VAG 1582 Tapered roller bearing puller
^ VAG 1582/6 Grip
^ Kukko 44/2 Puller





Note:
^ Heat tapered roller bearing inner race to 100° before installing.
^ Always replace both tapered roller bearings together as a set.
^ If tapered roller bearings for the differential housing, final drive cover, drive pinion set and the rear axle housing are replaced the differential must be adjusted.

Note: Components marked with [1] require adjustment work when they are replaced, Refer to Adjustment overview.

Clamp rear final drive in assembly bracket; Refer to Fig. 1

1. Cover for rear final drive[1]
2. Seal
^ Always replace
^ Insert with oil
3. Rear axle housing[1]
4. Shim S1
5. Small tapered roller bearing outer race [1]
^ Driving out; Refer to Fig.1
^ Pressing in; Refer to Fig.2
6. Small tapered roller bearing inner race [1]
^ Pulling off; Refer to Fig.3
^ Pressing on; Refer to Fig.4
7. Hex bolt, 60 Nm then turn 45° further
^ Always replace
^ Lightly tighten bolts then tighten diagonally to correct torque
^ Part No: Replacement parts Supplier
8. Differential cage[1]
9. Ring gear [1]
^ Is mated to pinion shaft (pinion set)
^ Drive off with a drift; Refer to Fig 9
^ Install on differential housing; Refer to Fig. 10
^ Determine according to transmission code letters using parts catalog
10. Spring pin
^ For securing differential bevel gear axis shaft
^ Drive in flush
11. Large tapered roller bearing inner race [1]
^ Pulling off - Fig.5
^ Pressing on - Fig.6
12. Large tapered roller bearing outer race [1]
^ Driving out - Fig.7
^ Pressing in - Fig.8
13. Shim S2
^ Note thickness
14. Threaded piece
15. Large differential bevel gear
^ Installing; Refer to Fig. 11
16. Small differential bevel gear
^ Installing; Refer to Fig. 11
17. Differential bevel gear axis shaft
^ Drive out with drift
18. Shim
19. Thrust washer
^ Check for cracks





Fig. 1 Driving small tapered roller bearing outer race out of housing

- After removing check shims for damage.





Fig. 2 Pressing small tapered roller bearing outer race onto stop in housing





Fig. 3 Pulling off small tapered roller bearing inner race

A - Commercially available two arm puller, e g. Kukko 44/2





Fig. 4 Pressing on small tapered roller bearing inner race

WARNING!: Wear protective gloves!

- Heat inner ring to approximately 100° before pressing on.





Fig. 5 Pulling off large tapered roller bearing inner race

- Before mounting extractor position press piece 40-105 on differential housing.





Fig. 6 Pressing on large tapered roller bearing inner race

WARNING!: Wear protective gloves!

- Heat inner ring to approximately 100° before pressing on.





Fig. 7 Driving tapered roller bearing outer race out of cover

- After removing check shims for damage.





Fig. 8 Pressing tapered roller bearing outer race into cover





Fig. 9 Driving ring gear off housing





Fig. 10 Installing ring gear

WARNING!: Wear protective gloves!

- Heat ring gear to about 100° and install.

Note:
^ When installing ring gear, guide with centralizing pins -A- (local manufacture).
^ Observe work safety regulations.





Fig. 11 Installing large and small differential bevel gears

Note: Redetermine shims if large bevel gears have been replaced.

- Insert large bevel gears with redetermined shims.
- Insert small bevel gears turned through 180- and pivot into position (arrow).
- Insert thrust washers and align.
- Insert threaded pieces ensuring they are seated correctly.
- Drive differential bevel gear axis shaft into final position and secure.

Adjusting large and small differential bevel gears
- Insert large bevel gears with 0.5 mm thick shims.
- Insert small bevel gears turned through 180° with thrust washers.

Note: Ensure that the thrust washer positions are not interchanged now.

- Drive in bevel gear axis shaft.
- Press small bevel gears outward.





- Press large bevel gears in direction of arrows and check play.
- Determine thickest shim (that can still just be installed) for large bevel gear on each side.





Table of shims
- Determine shims via parts Supplier.





Note: If the bearing clearance cannot be measured, but the bevel gears can just still be turned, the adjustment is acceptable.