Volkswagen Workshop Service and Repair Manuals

Removing and installing differential   Note t  If tapered roller bearings are to be reused, mark the adjusting ring → Fig.. t  The pinion shaft does not need to be removed in order to remove and install the differential.

1 -	Gearbox housing

2 -	Speedometer drive

q	With marking for indicating oil level → Fig.

3 -	Output shaft for drive flange

q	Install with thread facing drive flange

q	Remove before removing differential

q	Install only after adjusting differential

4 -

O-ring

q	Always renew

5 -	Adjusting ring

q	Removing → Fig.

q	If used bearings are to be refitted, mark installation position before removal and reinstall in marked position → Fig.

q	When installing new bearings, pay attention to adjustment instructions ⇒ Adjusting differential, → Chapter

6 -	Drive flange oil seal

q	Before installing, pack space between sealing lips with multi-purpose grease

q	Can be renewed with gearbox installed → Chapter

q	Remove with oil seal extractor lever -VW 681-

q	Driving in → Fig.

7 -	Tapered ring

q	Shoulder faces thrust washer

8 -	Thrust washer

q	Place over compression spring

9 -	Compression spring

10 -	Drive flange

q	Insert with tapered ring, thrust washer and compression spring

q	Remove before removing inner retaining ring on differential bevel gear

q	Removing and installing → Fig.

11 -	Dished washer

12 -	Retaining ring

13 -	Sealing cover

14 -	Locking element

15 -	Bolt, 12 Nm

16 -	Sealing cover

17 -	Retaining ring

18 -	Dished washer

19 -	Drive flange

q	Insert with tapered ring, thrust washer and compression spring

q	Remove before removing inner retaining ring on differential bevel gear

q	Removing and installing → Fig.

20 -	Compression spring

21 -	Thrust washer

q	Place over compression spring

22 -	Tapered ring

q	Shoulder faces thrust washer

23 -	Drive flange oil seal

q	Before installing, pack space between sealing lips with sealing grease -G 052 128-

q	Can be renewed with gearbox installed → Chapter

q	Remove with oil seal extractor lever -VW 681-

q	Driving in → Fig.

24 -	Bearing body, 150 Nm

q	When installing new bearings, pay attention to adjustment instructions ⇒ Adjusting differential, → Chapter

q	Remove using slotted nut wrench -3155-

q	Installing → Fig.

25 -

O-ring

q	Always renew

26 -	Output shaft for drive flange

q	Install with thread facing drive flange

q	Remove before removing differential

q	Install only after adjusting differential

27 -	Differential

q	Dismantling and assembling → Chapter

q	Before removing differential, take out bearing body, adjusting ring and output shafts

28 -	Bolt, 12 Nm

29 -	Locking element

30 -	Retaining ring

q	First remove drive flange before removing retaining ring

q	Removing and installing → Fig.

31 -	Retaining ring

q	First remove drive flange before removing retaining ring

q	Removing and installing → Fig.

32 -

Seal

q	Always renew

33 -

Cover

q	For differential

34 -	Bolt, 28 Nm

q	Insert with locking fluid -AMV 185 101 A1-

After adjusting tapered roller bearings, secure bearing body and adjusting ring.

Driving in drive flange oil seal to stop

Marking adjusting ring –  If used bearings are to be refitted, mark installation position before removal -arrow- and reinstall in marked position.

Removing adjusting ring

Removing and installing drive flange   Note Drive flange can also be removed with drive flange installing tool -VW 391-.

Inserting differential and screwing in bearing body to stop to 150 Nm

Inserting retaining ring -arrow- –  Remove retaining ring with two screwdrivers.

Speedometer drive –  With gearbox installed, check gear oil level in final drive → Chapter.