Differential: Service and Repair
Differential
Special tools, testers and auxiliary items required
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415 A)
• Thrust Piece (40-105)
• Thrust Pad (3005)
• Tube (3259)
• Tube (3296)
• Press Tube (3345)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to VAG 1582 (V.A.G 1582/6A)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Puller 65-160 mm (18/1)
• Kukko Separating Tool 12-75 mm (17/1)
• Kukko Support (22/2)
• Heat the inner race/tapered roller bearing to 100 °C (212 °F) before installing.
• Replace both tapered roller bearings together.
• Adjust the differential (refer to => [ Differential, Adjusting ] Final Drive, Differential (02Q Transmission)) when replacing the tapered roller bearing, differential housing, transmission housing or clutch housing.
1 Transmission Housing
2 Adjusting Shim
• For the differential.
• To select the correct thickness, refer to => [ Differential, Adjusting ] Final Drive, Differential (02Q Transmission).
3 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Outer Race/Tapered Roller
Bearing from the Transmission Housing ].
• Installing, refer to => [ Installing the Outer Race/Tapered Roller
Bearing into the Transmission Housing ].
4 Inner Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Inner Race/Tapered Roller
Bearing ].
• Installing, refer to => [ Installing the Inner Race/Tapered Roller
Bearing ].
5 Differential Housing
• With a riveted final drive gear.
6 Inner Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Inner Race/Tapered Roller
Bearing ].
• Installing, refer to => [ Installing the Inner Race/Tapered Roller
Bearing ].
7 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Outer Race/Tapered Roller
Bearing from the Clutch Housing ].
• Installing, refer to => [ Pressing the Outer Race/Tapered Roller
Bearing with Shim into the Clutch Housing ].
8 Washer
• Installed position: the shoulder on the inner diameter faces the seal => [ (Item 13) Seal ].
9 Clutch Housing
10 Bolt
• 33 Nm
• Install with the threaded piece => [ (Item 22) Threaded Piece ].
11 Right Flange Shaft
12 Ring
• Pry the ring off the flange shaft => [ (Item 11) Right Flange Shaft ] with a screwdriver.
• Installed position: the depression points away from threaded holes in the flange shaft.
• Install the ring all the way by hand.
• The ring must lock into the flange shaft.
13 Seal
• For the right flange shaft
• Replace when the transmission is installed. Refer to => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
14 Flange Shaft Pressure Spring
• Installed behind the flange shaft.
15 Thrust Washer
• Installed position: the collar faces toward the spring, and tab, if equipped, faces toward tapered ring.
16 Tapered Ring
• Installed position: ball toward the differential housing.
17 Locking Ring
• Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed.
18 Large Differential Bevel Gear
• Installing, refer to => [ Installing the Differential Bevel Gears ].
19 Differential Taper Axle
• Remove using a drift.
• Installing, refer to => [ Installing the Differential Bevel Gears ].
20 Adapter Sleeve
• To secure the differential bevel gear axle.
• Removing and installing, refer to => [ Removing and Installing the Roll Pin
for the Differential Bevel Gear Axle ].
21 Small Differential Bevel Gear
• Installing, refer to => [ Installing the Differential Bevel Gears ].
22 Threaded Piece
• Installing => [ Installing the Differential Bevel Gears ].
23 Thrust Washer Union
• Install using transmission fluid.
24 Ring
• Pry the ring off the flange shaft => [ (Item 25) Left Flange Shaft ] with a screwdriver.
• Installed position: the depression points away from threaded holes in the flange shaft.
• Install the ring all the way by hand.
• The ring must lock into the flange shaft.
25 Left Flange Shaft
26 Seal
• For the left flange shaft.
• Replace when the transmission is installed. Refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
A Counter-support, for example, kukko support (22/2)
B Internal puller 46 to 58 mm, for example, kukko extractor 46-58 mm (21/7)
• Replace the washer.
Pressing the Outer Race/Tapered Roller Bearing with Shim into the Clutch Housing
- Install the washer beforehand.
• Pay attention to the shim installed position.
• The collar on the inner circumference faces the seal.
Removing the Inner Race/Tapered Roller Bearing
- Before installing the puller, mount the thrust piece (40-105) onto the differential housing.
Installing the Inner Race/Tapered Roller Bearing
Removing the Inner Race/Tapered Roller Bearing
A Puller, for example, kukko puller 65-160 mm (18/1)
B Separating tool 12 to 75 mm, for example, kukko separating tool 12-75 mm (17/1)
Installing the Inner Race/Tapered Roller Bearing
The cage wit the tapered rollers must rotate easily when being installed.
Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
A Counter-support, for example, kukko support (22/2)
B Internal puller 46 to 58 mm, for example, kukko extractor 46-58 mm (21/7)
Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing
- Support the transmission housing directly under the bearing mount using the press tube (3345).
Removing and Installing the Roll Pin for the Differential Bevel Gear Axle
Removing
- Cover the inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.
- Remove the adapter sleeve using a drift.
Installing
- Drive into the differential housing up to the stop.
Installing the Differential Bevel Gears
- Insert the thrust washer union with transmission fluid.
- Install and secure both large differential planetary gears, for example, with a flange shaft.
- Insert the small differential planetary gears 180° offset and pivot them into position.
- Press the differential bevel gear - arrow A - up to the first small differential bevel gear.
- Insert threaded pieces - arrow B - into the large differential planetary gears.
Installed position: shoulder faces the differential bevel gear
- Install the differential bevel gear axle up the end position and secure it with a new spring pin.