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) , or equivalent
• Kukko Extractor 46-58 mm (21/7)
• Kukko Support (22/2)
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
- First , remove the right flange shaft seal. 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/Tapered 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/Tapered Roller Bearing
• Both tapered roller bearing inner races are pressed on 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 mount.
Differentiating the Roll Pins
Allocation, Differential Housing
- Check the hole in the differential housing for the roll pin.
The hole in the differential housing was modified due to the longer roll pin.
Roll Pin with a 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 chisel.
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 3.0 mm - a - , using a mandrel - 1 -.
• The roll pin must not come in contact with the transmission 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 points toward the differential bevel gear
- Install the differential bevel gear axle up the end position and secure it with a new roll 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 -.