Skoda Workshop Service and Repair Manuals

Disassembling and assembling differential gear Special tools and workshop equipment required t  Counterholder -MP1-223 (3067)- t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Pressure spindle -MP3-408 (VW 412)- t  Pipe section -MP3-409 (VW 418 A)- t  Drive bushing -MP3-427 (40-21)- t  Pressure spindle -MP3-448 (VW 408 A)- t  Thrust piece -MP3-459 (VW 473) - t  Thrust plate -MP3-464 (30-205)- t  Thrust plate -MP3-467 (40-105)- t  Thrust piece -MP3-468 (2007)- t  Bushing -MP3-474 (3144)- t  Tapered-roller bearing extractor -V.A.G 1582- t  Gripper -V.A.G 1582/3- t  Interior extractor 46 up to 58 mm, e.g. -Kukko 21/7- t  Countersupport e.g. -Kukko 22/2-

t	Before installing heat the inner ring of the tapered-roller bearing to 100°C.

t	Replace both tapered-roller bearings together.

t	Removing and installing differential gear → Chapter.

t	When replacing the tapered-roller bearings, the differential housing, the gearbox housing or the clutch housing, set the differential gear → Chapter.

1 -	Gearbox housing

2 -	Adjusting washer

q	for the differential gear

q	Determine thickness → Chapter

3 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

4 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

5 -	Differential gear housing

q	with gear pinion for final drive

q	The hole of the tensioning sleeve is adapted to the length of the tensioning sleeve → Fig.

q	Assignment → Electronic Catalogue of Original Parts

6 -	Drive wheel for speedometer

q	if present, place it on the differential gear housing up to the stop before pressing on the inner ring Pos. 7

7 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

8 -	Outer ring/tapered-roller bearing

q	pressing out → Fig.

q	installing → Fig.

9 -	Clutch housing

10 -	Gasket ring with bushing

q	for right flange shaft

q	one-piece (a component part)

q	replace gasket ring together with bushing in the event of damage to the gasket ring → Chapter

11 -

25 Nm

q	screw to threaded connector Pos. 19 to attach the flange shaft

12 -	Flange shaft

q	left - removing and installing → Chapter

q	right - removing and installing → Chapter

13 -	Pressure spring for flange shaft

q	fitted behind flange shaft

14 -	Thrust washer

q	Fitting position: Collar towards pressure spring → Fig.

15 -	Conical ring

q	with slots for thrust washer catch

q	Fitting position: Cone towards differential gear housing

16 -

Circlip

q	holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed

17 -	Stop disc compound

q	insert with gear oil

18 -	Large differential bevel gear

q	installing → Fig.

19 -	Threaded part

q	installing → Fig.

20 -	Differential bevel gear shaft

q	remove in combination with short tensioning sleeve → Fig.

q	remove in combination with long tensioning sleeve → Fig.

q	installing → Fig.

21 -	Tensioning sleeve

q	to secure the differential bevel gear shaft

q	Tensioning sleeves having different lengths are mounted

q	Difference between the tensioning sleeves → Fig.

q	short tensioning sleeve: removing and installing → Fig.

q	long tensioning sleeve: is cut when removing → Fig.

q	long tensioning sleeve: installing → Fig.

22 -	Small differential bevel gear

q	installing → Fig.

23 -	Sealing ring

q	for left flange shaft

q	replace with installed gearbox → Chapter

Press outer ring/tapered-roller bearing out of clutch housing –  First remove gasket ring with bushing for right flange shaft.

Press outer ring/tapered-roller bearing into the clutch housing No adjusting washer is fitted at the side of the clutch housing.

Removing inner ring/tapered-roller bearing –  Before fitting the extractor, position pressure plate -MP3-467 (40-105) - on the differential gear housing.   Note Both inner rings/tapered-roller bearings of the differential gear housing are removed in the same way.

Press on inner rings/tapered-roller bearing   Note The inner rings/tapered-roller bearings for the gearbox housing and clutch housing are pressed on with the same special tools.

Remove outer ring/tapered-roller bearing from gearbox housing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-

Press in outer ring/tapered-roller bearing in the gearbox housing –  Position adjusting washer under outside ring. –  Support the gearbox housing with a bushing -MP3-474 (3144) - directly below the bearing support.

Difference between the tensioning sleeves

Dimension „a“ (mm)	Distinguishing feature
28.5 (short tensioning sleeve), removing and installing → Fig.	round slot -arrows-
36.0 (long tensioning sleeve), remove → Fig., install → Fig.	no round slot

Assign differential gear housing –  Check the hole for the tensioning sleeve in the differential gear housing. The hole in the differential gear housing was adapted due to the longer tensioning sleeves.

Bore	Length of tensioning sleeve (mm)
-A-	28.5 (short tensioning sleeve)
-A- and -B-	36.0 (long tensioning sleeve)

Tensioning sleeve with round slot (short tensioning sleeve): removing and installing Removing –  Cover inner ring/tapered-roller bearing and drive wheel for speedometer to avoid any possible damage and swarf. –  Drive out tensioning sleeve with a chisel, position the chisel in the circular slot. –  Press off the differential bevel gear shaft using an extractor. Install –  Drive the new tensioning sleeve into the differential gear housing up to the stop.

Remove tensioning sleeve without round slot (long tensioning sleeve); press out differential bevel gear shaft When pressing out the tensioning sleeve, it is sheared off during this procedure. –  Drive the remaining part of the tensioning sleeve out of the differential gear housing and the differential bevel gear shaft.

Install tensioning sleeve without round slot (long tensioning sleeve) –  Align the hole in the differential bevel gear shaft to the hole in the differential gear housing. –  Drive in the new tensioning sleeve with a drift -1- to the dimension -a- = 3.0 mm. l  When turning, the tensioning sleeve must not come in contact with the housing wall of the clutch housing when the differential gear is installed.

Install differential bevel gears and differential gear shaft –  Install stop disc compound with gearbox oil. –  Insert both large differential bevel gears and secure (e.g. with flange shaft). –  Insert the small differential bevel gears offset at 180° and slide in. –  Push in the differential bevel gear shaft -arrow A- up to the first small differential bevel gear. –  Insert the threaded parts -arrows B- in the large differential bevel gears.    Fitting position: Shoulder towards differential bevel gear –  Drive in the differential gear shaft up to end position and secure with new tensioning sleeve.

Fitting position of thrust washer for the conical ring -1- The collar -arrow- points towards the pressure spring -B-. The lands -A- are available on certain gearboxes. The lands -A- point towards the conical ring -1-.