Differential: Service and Repair
Differential
Special tools, testers and auxiliary items required
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to VAG 1582 (V.A.G 1582/3)
• Thrust Disc (VW 412)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Thrust Piece (VW 473)
• Thrust Pad (30-205)
• Press Support-R&I Wheel Brg's (3144)
• Thrust Pad (2007)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Sleeve (40-21)
• Thrust Piece (40-105)
• Inductive Heat Unit (VAS 6414)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Support (22/2)
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
- Remove the right flange shaft seal first. Refer to => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
Installing the Outer Race/Tapered Roller Bearing into the Clutch Housing
There is no adjusting shim on the side of the clutch housing.
Removing the Bearing Inner Race/Taper Roller Bearing
- Before installing the puller, set the thrust piece (40-105) onto the differential housing.
• Both tapered roller bearing inner races are pulled off from the differential housing in the same way.
Installing the Bearing Inner Race/Taper Roller Bearing
• Both tapered roller bearing inner races are pressed on from the differential housing in the same way.
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
- Install the adjusting shim under the outer race.
- Support the transmission housing with the press support-R&I wheel brg's (3144) directly under the bearing support.
Differentiating the Roll Pins
Allocation, Differential Housing
- Check the hole in the differential housing for the adapter sleeve.
The hole in the differential housing was modified due to the longer spring pin.
Roll Pin with Groove (Short Roll Pin): Removing and Installing
Removing
- Cover the inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.
- Remove the roll pin using a punch.
Installing
- Drive into the differential housing up to the stop.
Roll Pin without a Surrounding Groove (Long Roll Pin), Removing: Pressing out of the Differential Bevel Gear Axle
The roll pin is sheared off when it is removed.
- Drive the remaining part of the roll pin out of the differential housing.
Roll Pin without a Surrounding Groove (Long Roll Pin), Installing
- Align the hole in the differential bevel gear axle to the hole in the differential housing.
- Install the new roll pin to dimension - a - = 3.0 mm using a mandrel - 1 -.
• The roll pin must not come in contact with the transmission housing when the differential housing is installed.
On some Transmissions, the Thrust Washer Union has a Ridge - A -.
Also, the differential housing has a groove - B - all the way around it.
- Insert the thrust washer union using transmission fluid.
- Install the thrust washer union so that it fits into the groove - B - in the differential housing.
Installing the Differential Planetary Gears and Differential Bevel Gear Axle
- Insert the thrust washer union using 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 the threaded pieces - arrow B - into the large differential planetary gears.
Installed position: Collar toward the differential bevel gear
- Install the differential bevel gear axle up the end position and secure it with a new spring pin.
Installed Position: Tapered Ring Thrust Washer - 1 -
The collar - arrow - faces the pressure spring - B -.
Some transmissions are not equipped with ridges - A -.
The ridges - A - face the tapered ring - 1 -.