Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Drift -VW 295-

t	Thrust piece -VW 554-

t	Thrust pad -VW 510-

t	Thrust piece -3002-

t	Puller -V.A.G 1582-

t	Grip -V.A.G 1582/3-

t	Press tool -VW 412-

t	Thrust piece -VW 454-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t  Press tool -VW 408 a-

t  Installing sleeve -VW 455-

t	Heat tapered roller bearing inner race to 100° C before installing.

t	Always renew both tapered roller bearings together as a set.

t	If tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed, adjust differential → Chapter.

1 -	Hexagon socket head bolt, 25 Nm

q	Screw into threaded piece → Item.

2 -	Flange shaft

q	Removing and installing → Chapter

3 -	Compression spring for flange shaft

q	Installed behind flange shafts

4 -	Thrust washer

q	Installation position: shoulder faces spring, lugs face tapered ring

5 -	Tapered ring

q	With grooves to engage in thrust washer

q	Installation position: taper towards differential cage

6 -	Retaining ring

q	Holds tapered ring, thrust washer and spring in position when flange shaft is removed.

7 -	Gearbox housing

8 -	One-piece thrust washer

q	Coat with gearbox oil when installing

9 -	Large differential bevel gear

q	Installing → Fig.

10 -	Threaded piece

q	Installing → Fig.

11 -	Differential pinion pin

q	Drive out using drift

q	Installing → Fig.

12 -	Spring pin

q	For securing differential pinion pin

q	Removing and installing → Fig..

13 -	Small differential bevel gear

q	Installing → Fig.

14 -

Rivet

q	Only in production

q	Drilling out → Fig.

15 -

Shim S2

q	Always 1 mm thick

16 -	Tapered roller bearing outer race

q	Driving out → Fig.. First remove sleeve ( → Item).

q	Driving in → Fig.

17 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

18 -	Clutch housing

19 -	Repair kit

q	Only for Service department.

q	Installing → Fig.

q	Hexagon nut, 65 Nm

20 -	Final drive gear wheel

q	Riveted in production.

q	Paired with output shaft. Renew only as a set.

q	Pressing off → Fig..

q	Installation position → Fig.

q	Heat to 100 °C before installing.

q	Fit to differential cage → Fig.

q	Bolted → Fig..

21 -	Differential cage

22 -	Tapered roller bearing outer race

q	Driving out → Fig.

q	Driving in → Fig.

23 -

Shim S1

q	Determining thickness →

24 -

Seal

q	Renewing → Chapter

25 -

Sleeve

q	To support oil seal.

q	Removing and installing → Fig.

Driving tapered roller bearing outer race out of clutch housing

Driving tapered roller bearing outer race into clutch housing

Pulling off tapered roller bearing inner races –  Before setting up extractor, position press tool -3002- on differential housing.   Note Both tapered roller bearing inner races are pulled off the differential cage in the same way.

Pressing on tapered roller bearing inner race   Note The tapered roller bearing inner races for gearbox housing and clutch housing are pressed on with the same press tools.

Driving tapered roller bearing outer race out of gearbox housing

Driving tapered roller bearing outer race into gearbox housing

Drilling out rivet heads –  Drill out rivet heads with 12 mm drill bit from countersunk side and drive rivet out with drift.   Note Clean differential before and after drilling, protecting tapered roller bearing from drillings.

Removing and installing spring pin for differential pinion pin Removing –  Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles. –  Drive out spring pin with chisel, inserting chisel into circumferential groove. Installing –  Drive into differential cage to stop.

Pressing off final drive gear

Installation position of final drive gear The circular groove -A- faces bolt-on surface of differential housing.

Heating final drive gear wheel to approx. 100 °C and installing –  Use bolts -A- from repair kit to guide final drive gear into position during installation.

Bolting final drive gear and differential cage together Use special bolts with backing plates and nuts according to → Electronic parts catalogue “ETKA”.

Installing differential bevel gears –  Lubricate one-piece thrust washer with gearbox oil and install. –  Install both sun wheels and secure (e.g. with flange shaft). –  Insert planet pinions offset 180° and pivot into position. –  Press in differential pinion pin (-arrow A-) to first planet pinion. –  Set threaded pieces (-arrows B-) in sun wheels. Installation position: shoulder to bevel gear –  Drive differential pinion pin into final position and secure with spring pin.