Differential, Disassembling and Assembling
Differential, Disassembling and Assembling
Special tools, testers and auxiliary items required
• Taper roller bearing puller (V.A.G 1582)
• Attachment (V.A.G 1582/3)
• Punch (VW 412)
• Pressure plate (VW 401)
• Pressure plate (VW 402)
Special tools, testers and auxiliary items required
• Punch (VW 408 A)
• Thrust piece (VW 473)
• Thrust piece (30 - 205)
• Sleeve (3144)
• Thrust piece (2007)
• Torque Wrench (V.A.G 1332)
Special tools, testers and auxiliary items required
• Internal puller (1- Kukko 21/7)
• Counter support (4- Kukko 22/2)
• Heat inner race/tapered roller bearing to 100 °C before installing.
• Always replace both taper roller bearings together as a set.
• Adjust differential --> [ Adjustment Overview ] Adjustment Overview when replacing tapered roller bearing, differential housing, transmission housing and clutch housing.
1 Transmission housing
2 Adjustment shim
• For differential
• Determining thickness --> [ Differential, Adjusting ] Differential, Adjusting
3 Tapered roller bearing outer race
• Pulling out --> [ Pulling outer race/tapered roller bearing out of transmission housing ]
• Installing --> [ Pressing outer race/tapered roller bearing into transmission housing ]
4 Tapered roller bearing inner race
• Pulling off --> [ Pulling off inner races/tapered roller bearing ]
• Pressing on --> [ Pressing on inner races/tapered roller bearing ]
5 Differential housing
• With gear-wheel for final drive
• Thrust washer union fitted to differential housing --> [ On some transmissions the thrust washer union was made with a ridge in the area of the holes. ]
• Spring pin hole adapted to the length of the spring pin --> [ Differential housing allocation ]
• Allocation
6 Tapered roller bearing inner race
• Pulling off --> [ Pulling off inner races/tapered roller bearing ]
• Pressing on --> [ Pressing on inner races/tapered roller bearing ]
7 Tapered roller bearing outer race
• Removing --> [ Pressing tapered roller bearing outer race out from clutch housing ]
• Installing --> [ Pressing outer race/tapered roller bearing into clutch housing ]
8 Clutch housing
9 Sleeve
• Removing and installing --> [ Transmission Housing and Clutch Housing, Servicing ] Transmission Housing and Clutch Housing, Servicing
10 Seal
• Left flange shaft seal, inserting with transmission installed --> [ Left Flange Shaft Seal, Replacing ] Left Flange Shaft Seal, Replacing
• Right flange shaft seal, inserting with transmission installed (right flange shaft and sleeve seal consist of two parts) --> [ Two-Piece Right Flange Shaft Seal and Sleeve, Replacing ] Two-Piece Right Flange Shaft Seal and Sleeve, Replacing
11 Oil seal and sleeve as one part
• If seal is damaged, replace seal and sleeve together --> [ One-Piece Right Flange Shaft Seal and Sleeve, Replacing ] One-Piece Right Flange Shaft Seal and Sleeve, Replacing
12 Countersunk bolt, 25 Nm
• Install together with threaded piece --> [ 20 Threaded piece ]
13 Flange shaft
• Removing and installing --> [ Left Flange Shaft Seal, Replacing ] Left Flange Shaft Seal, Replacing
14 Spring for flange shaft
• Installed behind flange shafts
15 Thrust washer
• Installation position --> [ Installation position of thrust washer for tapered ring ]
16 Tapered ring
• With grooves to engage thrust washer
• Installation position: Taper toward differential housing
17 Securing ring
• Holds tapered ring, thrust washer and compression spring in position with flanged shaft removed
18 Thrust washer union
• Install coated with gear oil
• On some transmissions, the thrust washer union was made with a ridge --> [ On some transmissions the thrust washer union was made with a ridge in the area of the holes. ]
19 Large differential bevel gear
• Installing --> [ Differential bevel gears and differential bevel gear axle, installing ]
20 Threaded piece
• Installing --> [ Differential bevel gears and differential bevel gear axle, installing ]
21 Differential planetary gear axle
• Removing, in conjunction with a short spring pin --> [ Spring pin with surrounding groove (short spring pin): removing and installing ]
• Removing, in conjunction with a long spring pin --> [ Removing spring pin without surrounding groove (long spring pin): Press out differential bevel gear axle. ]
• Installing --> [ Differential bevel gears and differential bevel gear axle, installing ]
22 Spring pin
• For securing axle for differential bevel gears
• Different lengths of spring pins are installed
• Differentiating the spring pins --> [ Differentiating the spring pins ]
• Short spring pin: removing and installing --> [ Spring pin with surrounding groove (short spring pin): removing and installing ]
• Long spring pin: sheared off at removal --> [ Removing spring pin without surrounding groove (long spring pin): Press out differential bevel gear axle. ]
• Long spring pin: Installing --> [ Spring pin without surrounding groove (long spring pin), installing ]
23 Small differential bevel gear
• Installing --> [ Differential bevel gears and differential bevel gear axle, installing ]
24 Large differential bevel gear
• Installing --> [ Differential bevel gears and differential bevel gear axle, installing ]
Pressing tapered roller bearing outer race out from clutch housing
- Remove mounting sleeve for flange shaft seal first.
Pressing outer race/tapered roller bearing into clutch housing
No shim will be installed on the side of the clutch housing.
Pulling off inner races/tapered roller bearing
- Before installing puller, set thrust piece (40 - 105) onto differential housing.
• Both tapered roller bearing inner races are pulled off from the differential housing in the same way.
Pressing on inner races/tapered roller bearing
• Tapered roller bearing inner race for transmission housing and clutch housing are pressed on using the same special tools.
Pulling outer race/tapered roller bearing out of transmission housing
A Support, e.g. (Kukko 22/2)
B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)
Pressing outer race/tapered roller bearing into transmission housing
- Install shim under outer race.
- Support transmission housing directly beneath bearing mount using press support (3144).
Differentiating the spring pins
Differential housing allocation
- Check spring pin hole in the differential housing.
The hole in the differential housing was modified due to the longer spring pin.
Spring pin with surrounding groove (short spring pin): removing and installing
Removing
- Cover taper roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.
- Drive out spring pin with chisel, inserting chisel into circumferential groove.
Installing
- Drive into differential housing up to the stop.
Removing spring pin without surrounding groove (long spring pin): Press out differential bevel gear axle.
Spring pin is sheared off when pressing out.
- Drive remaining part of roller pin out of differential housing.
Spring pin without surrounding groove (long spring pin), installing
- Align the hole in the differential bevel gear axle to the hole in the differential housing.
- Drive a new spring pin in to dimension - a - = 3.0 mm using a drift - 1 -.
• The spring pin must not come in contact with the transmission when the differential housing is installed.
On some transmissions the thrust washer union was made with a ridge - A - in the area of the holes.
In conjunction with this, the differential housing had a circumferential groove - B -.
- Insert thrust washer union with transmission fluid.
- Install thrust washer union so that it engages into the groove - B - of the differential housing.
Differential bevel gears and differential bevel gear axle, installing
- Insert thrust washer union with transmission fluid.
- Insert both large differential bevel gears and secure (e.g. with flange shaft).
- Insert small differential planetary gears 180° offset and pivot them into position.
- Press in differential bevel gear axle - arrow A - up to first small differential bevel gear.
- Insert threaded pieces - arrows B - in large differential bevel gears
Installation position: Shoulder faces toward differential bevel gear
- Drive differential planetary gear axle into final position and secure with spring pin.
Installation position of thrust washer for tapered ring - 1 -
The collar - arrow - faces toward the spring - B -.
Some transmissions are equipped with ridges - A -.
The ridges - A - face toward the tapered ring - 1 -.