Differential
Differential
Special tools, testers and auxiliary items required
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Thrust Piece (40-105)
• Thrust Pad (3005)
• Thrust Piece (VW 473), with right stub shaft
• Tube 60 mm dia. (VW 415 A), with right flange shaft
• Tube (3259)
• Tube (3296)
• Press Tube (3345)
• Taper Roller Bearing Puller (V.A.G 1582)
• Attachment to VAG 1582 (V.A.G 1582/6A)
• Kukko Extractor (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.
• Always replace both tapered roller bearings together as a set.
• Adjust the differential, refer to => [ Differential, Adjusting ] Adjustments when replacing the tapered roller bearing, differential housing, transmission housing or clutch housing.
1 Transmission Housing
2 Adjustment Shim
• For the differential.
• Determining thickness, refer to => [ Differential, Adjusting ] Adjustments.
3 Outer Race/Tapered Roller Bearing
4 Bearing Inner Race/Taper Roller Bearing
5 Differential Housing
• With a riveted final drive gear wheel.
• Mounting - arrow - for right tapered roller bearing with insert of right flange shaft, 12.5 mm longer.
6 Bearing Inner Race/Taper Roller Bearing
7 Outer Race/Tapered Roller Bearing
8 Washer
Installed position: the collar on the inner circumference faces the seal.
9 Clutch Housing
10 O-ring
• Always replace.
11 Protective Ring
• Can be pulled off and pushed on to stub shaft - item 13 - by hand.
12 Countersunk Bolt
• 33 Nm
• Screw together with the threaded piece - item 26 -.
13 Stub Shaft
• As of transmission build date 1 November 2004, replaced by the flange shaft - item 15 -.
14 Oil Seal
• For the stub shaft, up to transmission build date 31 October 2004.
• Replace with the transmission installed. Refer to => [ Right Stub Shaft Seal, through 31 October 2004, Transmission Installed ].
15 Right Flange Shaft
• As of transmission build date 1 November 20044, replaces the stub shaft - item 13 -.
16 Protective Ring
• Pry off the protective ring from the flange shaft on alternating sides using a screwdriver.
• Press on the protective ring until seated by hand.
• Protective ring must engage with flange shaft.
17 Oil Seal
• For the flange shaft, as of transmission build date 1 November 2004.
• Replacing with transmission installed. Refer to => [ Right Flange Shaft Seal, from November 1 2004 ] Right Flange Shaft Seal, From November 1 2004.
18 Spring for Flange Shaft or Stub Shaft
• Installed behind flange shaft or stub shaft.
19 Thrust Washer
• Installed position: the collar faces toward the spring, and tab, if equipped, faces toward tapered ring.
20 Tapered Ring
• Installed position: ball toward the differential housing.
21 Securing Ring
• Holds the tapered ring, thrust washer and spring in position with the flange shaft or stub shaft removed.
22 Large Differential Bevel Gear
23 Differential Taper Axle
• Drive out using a drift.
24 Spring Pin
• For securing the axle for the differential bevel gears.
25 Small Differential Bevel Gear
26 Threaded Piece
27 Thrust Washer Union
• Install lubricated with transmission fluid.
28 Protective Ring
• Pry out the protective ring using a screwdriver alternately.
• Installed position: the depression points away from threaded holes in flanged shaft.
• Press on the protective ring until seated by hand.
• Protective ring must engage with flange shaft.
29 Flange Shaft
30 Oil Seal
• For the flange shaft.
• Replace with the transmission installed. Refer to => [ Right Stub Shaft Seal, through 31 October 2004, Transmission Installed ].
Pulling Outer Race/Tapered Roller Bearing off Clutch Housing
A Support, for example, (22/2)
B Internal puller 46 to 58 mm, for example, (21/7)
• Replace the washer after pulling out.
Pressing Outer Race/Tapered Roller Bearing with Shim into Clutch Housing
• Pay attention to the shim installed position.
• The collar on the inner circumference faces the seal.
Removing the Bearing Inner Race/Taper Roller Bearing
- Before installing the puller, set the (40-105) onto the differential housing.
Installing the Bearing Inner Race/Taper Roller Bearing
Removing the Bearing Inner Race/Taper Roller Bearing
A Extractor, for example, (18/1)
B Separating device 12 to 75 mm, for example, (17/1)
Transmission with Right Stub Shaft: Installing the Bearing Inner Race/Tapered Roller Bearing
- Place the (VW 473), with the smaller outer diameter, onto the inner race for tapered roller bearing.
Cage with tapered roller bearings must be able to be turned easily when pressing on.
Transmission with Right Flange Shaft: Installing the Bearing Inner Race/Tapered Roller Bearing
Cage with tapered roller bearings must be able to be turned easily when pressing on.
Pulling Outer Race/Tapered Roller Bearing out of Transmission Housing
A Support, for example, (22/2)
B Internal puller 46 to 58 mm, for example, (21/7)
Pressing in Tapered Roller Bearing Outer Race into Transmission Housing
- Support transmission housing directly beneath the bearing mount using the (3345).
Removing and Installing Roll Pin for Differential Bevel Gear Axle
Removing
- Cover inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.
- Drive out spring pin with chisel, inserting chisel into circumferential groove.
Installing
- Drive into the differential housing up to the stop.
Installing the Differential Bevel Gears
- Insert 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
- Drive differential planetary gear axle into final position and secure with spring pin.
USVK03589902-031010