Differential: Service and Repair
Differential
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Tube 31.5 mm Dia. (VW 418 A)
• Thrust Tube (VW 454)
• Thrust Tube (VW 455)
• Sleeve (VW 472/2)
• Thrust Pad (VW 510)
• Sleeve (30-14)
• Press Tube (2040)
• Thrust Pad (3002)
• Flywheel Retainer (3067)
• Tube (3259)
• Press Tool (3345)
• Taper Roller Bearing Puller (V.A.G 1582)
• Attachment to VAG 1582 (V.A.G 1582/4)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Support (22/2)
• Thrust Pad (30-205)
• Sleeve (40-21)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Attachment to VAG 1582 (V.A.G 1582/3)
• Inductive Heater (VAS 6414)
• Warm the bearing inner race/tapered roller bearing to approximately 100 °C (212 °F) using the (VAS 6414) before installing. Wear protective gloves.
• Replace both tapered roller bearings together.
• Adjust the differential (refer to => [ Differential, Adjusting ] Adjustments) when replacing the tapered roller bearing, differential housing, transmission housing or clutch housing.
1 Bolt
• 25 Nm
• Install with the threaded piece - item 8 -.
2 Right Flange Shaft
3 Flange Shaft Pressure Spring
• Installed behind the flange shaft.
4 Thrust Washer
• Installed position: Collar toward the spring.
5 Tapered Ring
• Installed position: differential housing taper.
6 Lock Ring
• Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed.
7 large Differential Bevel Gear
• Installing.
8 Threaded Piece
• Installing.
9 Differential Taper Axle
• Shear off roll pin - item 18 - to remove.
• Installing.
10 Small Differential Bevel Gear
• Installing.
11 Thrust Washer Union
• Install using transmission fluid.
12 Left Flange Shaft
13 Seal
• For the left flange shaft.
• Replace with the transmission installed. Refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
14 Adjusting Shim S1
• For the differential.
• Always 1 mm thick.
• Shim S1 is deleted as of production date 04 December 2006. Refer to => [ Shim S for
the Outer Race/Tapered Roller Bearing is Deleted as of Production
date 04 December 2006 ] Adjustments.
• Outer race/tapered roller bearing seat adapted in transmission housing,
• For the correct allocation, refer to the Parts Catalog.
15 Outer Race/Tapered Roller Bearing
• Removing.
• Installing.
16 Bearing Inner Race/Taper Roller Bearing
• Removing.
• Installing.
17 Differential Housing
• With the final drive gear.
18 Roll Pin
• To secure the differential bevel gear axle.
• Sheared off at removal.
19 Bearing Inner Race/Taper Roller Bearing
• Removing.
• Installing.
20 Outer Race/Tapered Roller Bearing
• Removing.
• Installing.
21 Adjusting Shim S2
• For the differential.
• Determining thickness, refer to => [ Differential, Adjusting ] Adjustments.
22 Seal
• For the right flange shaft.
• Replace with the transmission installed. Refer to => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
23 Transmission Housing
• Disassembling and assembling, refer to => [ Transmission Housing and Clutch Housing ] Transmission Housing and Clutch Housing.
• Shim S1 is deleted as of production date 04 December 2006. Refer to => [ Shim S for
the Outer Race/Tapered Roller Bearing is Deleted as of Production
date 04 December 2006 ] Adjustments.
• Outer race/tapered roller bear seat adapted.
• For the correct allocation, refer to the Parts Catalog.
24 Clutch Housing
• Disassembling and assembling, refer to => [ Transmission Housing and Clutch Housing ] Transmission Housing and Clutch Housing.
Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
A Counter-support, for example, (22/2)
B Internal puller 46 to 58 mm, for example, (21/7)
Installing the Outer Race/Tapered Roller Bearing to the Transmission Housing
- Support the transmission housing directly beneath the bearing mount using the (3259).
- See if a shim S1 must be inserted under the outer race. Refer to => [ Shim S for
the Outer Race/Tapered Roller Bearing is Deleted as of Production
date 04 December 2006 ] Adjustments.
- If necessary, place a 1 mm shim S1 under the outer race.
Removing the Bearing Inner Race/Taper Roller Bearing
Installing the Bearing Inner Race/Taper Roller Bearing
CAUTION!
Wear safety gloves.
- Heat the inner races/tapered roller bearing inner race to approximately 100 °C (212 °F) before installing.
- Support the bearing inner race on the opposite side using (VW 455).
(VW 455) shoulder faces toward the differential housing
Pressing the Tapered Roller Bearing Outer Race - A - Out from the Clutch Housing
B Internal puller 46 to 58 mm, for example, (21/7)
- Tension internal puller securely behind tapered roller bearing inner race.
Installing the Outer Race/Tapered Roller Bearing into the Clutch Housing
- Support the clutch housing directly beneath the bearing mount using (3345).
Removing the Bearing Inner Race/Taper Roller Bearing
- Place the (VW 472/2) and the (3002) on the differential housing before installing the puller.
Installing the Bearing Inner Race/Taper Roller Bearing
CAUTION!
Wear safety gloves.
- Heat the inner races/tapered roller bearing inner race to approximately 100 °C (212 °F) before installing.
Removing the Differential Bevel Gear Axle
Roll pin is sheared off when it is removed.
- Drive the remaining part of the roll pin out of the differential housing.
Installing the Differential Bevel Gears
- 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.
- Install the differential bevel gear axle up the end position and secure it with a new roll pin.