Skoda Workshop Service and Repair Manuals

Disassembling and assembling the differential gear Special tools and workshop equipment required t  Sealant -AMV188 200 03- t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Adapter for MP 3 - 403 -MP3-403/1 (VW 295 A)- t  Thrust piece -MP3-408 (VW 412)- t  Thrust piece -MP3-423 (VW407)- t  Drive bushing -MP3-427 (40-21)- t  Thrust piece -MP3-448 (VW 408 A)- t  Pressure washer -MP3-456 (VW 447 I)- t  Pressure plate -MP3-459 (VW 473)- t  Thrust plate -MP3-464 (30-205)- t  Thrust plate -MP3-467 (40-105)- t  Pressure plate -MP3-468 (2007)- t  Bushing -MP3-474 (3144)- t  Extractor for differential gear axle -MP3-510 - t  Separating device -Kukko 17/1- t  Extractor, e.g. -Kukko 18/1- t  Countersupport -Kukko 22/2- t  Interior extractor -Kukko 21/7-   Note t  Before installing heat the inner ring of the tapered-roller bearing to 100°C. t  Replace both tapered-roller bearings together. t  When replacing the tapered-roller bearing of the differential housing, gearbox housing and clutch housing adjust the differential → Chapter. t  Pos. 24, Pos. 25, Pos. 26, Pos. 27 and Pos. 28 only applies for service.

1 -	Screw, 25 Nm

q	screw to threaded connector to attach the flange shaft (⇒ Pos. 20)

2 -	Flange shaft

q	with hole for conical screw

q	removing and installing → Chapter

3 -	Pressure spring for flange shaft

q	fitted behind flange shaft

4 -	Thrust washer

q	Fitting position: Flange to pressure spring, leg to conical ring

5 -	Conical ring

q	with slots for thrust washer catch

q	Fitting position: Cone towards differential gear housing

6 -

Circlip

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

7 -	Gearbox housing

8 -	Clutch housing

9 -	Differential gear housing

q	with riveted pinion for final drive

q	when replacing the final drive pinion bore out the rivet heads → Fig.

q	Secure pinion for final drive with screws → Fig.

10 -	Coupling sleeve to angle gearbox

q	pressed onto differential housing

q	pulling off and pressing on only with the differential housing removed

q	remove → Fig.

q	pressing on → Fig.

11 -	Drive wheel for speedometer

q	before pressing on the inner ring place it on the differential gear housing up to the stop

12 -	Inner ring/tapered-roller bearing

q	before removal, pull off coupling sleeve (⇒ Pos. 10)

q	remove → Fig.

q	pressing on → Fig.

13 -	Outer ring/tapered-roller bearing

q	extracting → Fig.

q	installing → Fig.

14 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

15 -	Outer ring/tapered-roller bearing

q	extracting → Fig.

q	installing → Fig.

16 -	Adjusting washer

q	for the differential gear

q	Determine thickness → Chapter

17 -	Tensioning sleeve

q	to secure the differential bevel gear shaft

q	removing and installing → Fig.

18 -	Differential bevel gear shaft

q	drive out with -MP3-510-

q	installing → Fig.

19 -	Differential bevel gear small

q	installing → Fig.

20 -	Threaded part

21 -	Differential bevel gear large

q	installing → Fig.

22 -	Stop disc compound

q	insert with gear oil

23 -	Gasket ring

q	replace → Chapter

24 -

Screw

25 -	Differential gear housing

q	screwed to pinion for final drive → Fig.

26 -	Pinion for final drive

q	series riveted

q	screw → Fig.

q	heat to 100 °C before fitting

q	pressing off → Fig.

q	Fitting position → Fig.

q	place on differential housing → Fig.

q	is paired with the output shaft, replace together

27 -

Shim

28 -

70 Nm

Driving outer ring/tapered-roller bearing from clutch housing

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

Remove inner rings/tapered-roller bearing –  Before fitting the extractor position, position pressure plate -MP3-467- on the differential 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 bearing for the gearbox housing and clutch housing are pressed on with the same pressure 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 sleeve -MP3-474- directly below the bearing support.

Bore out rivet heads –  Bore out the rivet heads on the sunken side with a 12 mm drill and drive out rivets with a drift.   Note Clean differential gear before and after drilling, protect tapered-roller bearing from boring swarf.

Pressing off pinion/final drive –  Fit thrust plate -MP3-467- on the differential gear housing.

Fitting location of the pinion/final drive –  The circular slot -A- points to the screw-on surface of the differential gear housing.

Heat pinion/final drive to approx. 100°C and install –  Guide the pinion/final drive suring fitting with screws -A- from the repair kit.

Screw pinion/final drive and differential housing Use special screws from the repair kit for gerabox 02C.

Removing and installing the tensioning sleeve for differential bevel gear shaft 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. –  Drive out differential bevel gear shaft with -MP3-510-. Installing: –  Drive in the new tensioning sleeve into the differential gear housing up to the stop.

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

Pull off the coupling sleeve for the angle gearbox. A -  Coupling sleeve B -  Extractor, e.g. -Kukko 18/1 - C -  Separating device 12... 75 mm e.g. - Kukko 17/1-

Press on coupling sleeve -A- for angle gearbox