Operation CHARM: Car repair manuals for everyone.

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