Volkswagen Golf Workshop Service and Auto Repair Manuals

Differential bevel gear shaft secured with extended rivets

Play free location of drive flange shafts => page 39-19

• Bearing housing
• Shim S2
• Is always 1 mm thick
• Outer race
• ◆ Pulling out => fig. 9 .
• ◆ Knocking => fig. 10 .
• Shaft for drive flange
• ◆ Turn slightly when pulling out as thrust washer tends to catch.
• ◆ Press in carefully when installing, do not damage thrust washer.
• 70 Nm

• Crown wheel
• Is matched to output shaft.
• ◆ Press off => fig.4 .
• ◆ To fit, heat to 100° C => fig.5 .
• ◆ If gears are replaced, adjust output shaft
• Differential housing
• ◆ If replaced: Adjust differential
  
• Service parts
• ◆ Service only installing => fig. 6 .
• Bearing inner race
• ◆ Pull off => fig.1 .
• ◆ To fit, heat to 100° C and press fully home => fig.2 .
• ◆ Remove shaft for drive flange first.
• ◆ If replaced:
  Adjust differential
• Outer race
• ◆ Pulling out => fig. 11 .
• ◆ Knocking in => fig. 12 .
• Shim S1
• ◆ Find thickness

• Gearbox housing
• One-piece thrust washer
• ◆ Lubricate with gear oil before
  installing
• Differential pinions
• ◆ Install => fig. 7 .
• Pinion shaft
• Knock out with a drift, do not damage thrust washer when installing
• Rivet
• ◆ Production only drill out => fig. 3 .
• Bearing inner race
• ◆ Press off => fig.1 .
• ◆ To fit, heat to 100° C and press fully home => fig.2 .
• ◆ Remove shaft for drive flange first.
• ◆ If replaced:
  Adjust differential
• Circlip
• ◆ Find thickness =>fig. 8 .

→ Fig.1     Pulling inner race off

•      A -     Puller such as Kukko 20/1 with 100 mm reach hooks.

→ Fig.2     Pressing inner race home

Heat race to 100° first and install.

→ Fig.3     Drilling rivet heads

Drill rivets out with 12 mm drill from the centre punched or countersunk side and knock them out.

→ Fig.4     Pressing crown wheel off

→ Fig.5     Heat crown wheel to about 100° C and install

Guide crown on the housing with screws -A- from repair kit.

→ Fig.6     Bolt crown wheel to housing with special screws, washers and nuts - Part No. 171 498 088 (Repair Kit).

→ Fig.7     Installing differential pinions

• ‒ Lubricate one-piece thrust washer with gear oil and install it
• ‒ Insert small pinions, knock spindle in and secure.
• ‒ Insert large pinions offset 180° and swing in.

→ Fig.8     Find thickness of circlip -arrow-

•      1 -     Differential housing
•      2 -     Differential pinion spindle
•      3 -     Differential pinion
•      4 -     Differential gear
•      5 -     Drive flange shaft
•      6 -     Circlip

• ‒ Press shaft against differential pinion needle.
• ‒ Press differential gears against housing and press thick circlip into groove. If circlip jams at the sides, install thinner circlip.

The following circlips are available:

→ Fig.9     Knocking differential bearing outer race out of bearing housing

→ Fig.10     Knocking differential bearing outer race into bearing housing

→ Fig.11     Knocking differential bearing outer race out of gearbox housing

→ Fig.12     Knocking differential bearing outer race into gearbox housing