Differential, Removing and Installing
Differential, removing and installing, 012/01W, 5 SPD. M/T
Special tools, testers and auxiliary items required:
^ Slide Hammer-Complete Set VW 771
^ Plug Insert Sw27 3257
^ Torque Wrench 5-50 Nm V.A.G. 1331
^ - 1 - Internal extractor Kukko 21/3
Note:
^ Removal and installation is also possible with transmission installed.
^ The differential can be installed and removed without removing shift mechanism, drive flange and drive pinion. Removal of the components mentioned above is necessary if the differential must be adjusted.
^ Look for visible damage of polygon beatings.
^ Polygon beatings can only be replaced together with drive flange.
^ Rough running of the polygon beatings with the drive flange removed is no sign for faulty beatings. An acoustic test can only be performed in installed condition.
^ A spacer ring is installed between the polygon beating and differential pinion for drive flanges with a spline diameter of 30 mm, - item no. 5 -.
^ Adjustments are required when replacing components marked with 1).
1. Transmission housing 1)
^ Made out of aluminum, may only be installed with transmission cover made out of aluminum
^ Made out of magnesium, may only be installed with transmission cover made out of magnesium
2. Seal
^ Replace
^ Replace oil seals for flange shafts
3. Circlip
^ Replace
4. Spacer ring
^ Only installed for drive flanges with spline diameter of 30 mm
5. Flange shaft
^ Flange shaft design, fig.
6. Differential with ring gear
^ Can be installed without removal of transmission
^ Reinforcement measures as of transmission manufacture date 17 08 8 (phased in introduction)
7. Cover for final drive 1)
^ Made out of aluminum, may only be installed with transmission housing made out of aluminum
^ Made out of magnesium, may only be installed with transmission housing made out of magnesium
^ Identification
^ Reinforcement measures as of 08.98 (phased in introduction)
^ Coat sealing surfaces with a thin layer of sealant AMV 188 001 02
8. Torx bolt, 25 Nm
^ For transmissions made out of magnesium, bright, various length of bolts
^ Always replace
^ For transmissions made out of aluminum: black, M8 x 42, without washer
9. Drive gear for speedometer
^ Carefully install onto differential without canting. Do not use force, drive gear can break
Removing and installing securing ring
^ Clamp flange shaft in vise with protective jaws. Press circlip with new circlip - A - out of flange shaft groove.
Removing spacer ring
A - Internal puller 18.5 to 23.5 mm, e.g. Kukko 21/3
^ If spacer ring is tight, remove using slide hammer-complete set VW 771.
Installing spacer ring
^ Press in spacer ring to stop without canting.
Flange shaft design
1. Flange shaft
2. Needle bearing (polygon bearing)
3. Spacer ring
4. Circlip
5. Spacer ring (is installed additionally if spline diameter is 30 mm)
Note:
^ Needle beatings (polygon beating) are tight when flange shaft is removed. This does not indicate that beating is malfunctioning.
Marking of differential cover
On transmissions made out of magnesium, writing "Mg Al 9 Zn 1 " is located in area of arrow.
Mg = magnesium; additional information depends on manufacturing.
Arrangement of bolts for differential cover with transmission housing made out of magnesium
1. Bright bolts, M8 x 42 without washer
2. Bright bolts, M8 x 45 with permanent washer
^ In this area, bolts without washer must not be used.
Note:
^ Only M8 x 45 bolts with permanent washer are supplied as a replacement part and must be used for all threaded connections of the transmission cover, if necessary.
Reinforcement measures as of transmission manufacture date 17 08 8 (tapered roller bearing with larger inner and outer diameter) on left differential side (ring gear side). Implemented as a running change as of transmission manufacture date 17 08 8, but for all transmissions as of transmission manufacture date 11019.
The following parts are affected by this modification:
1. Differential housing
^ As of 05.03 the bearing seat for left tapered roller bearing on differential housing are provided with larger radius at inner stop. The inner race of left tapered roller bearing was also modified accordingly. Old version of tapered roller bearing cannot be installed with new differential housings.
2. Inner race for tapered roller bearing
^ Modified inner race of bearing as of 05.03
3. Tapered roller bearing outer race
4. Adjustment shim "S1"
5. Cover for final drive