Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/3-

t	Press tool -VW 412-

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 408 A-

t	Thrust piece -VW 473-

t	Thrust plate -30 - 205-

t	Sleeve -3144-

t	Thrust piece -2007-

t	Torque wrench -V.A.G 1332-

t  Internal puller -1-Kukko 21/7- t  Counter support -4-Kukko 22/2-

Pressing tapered roller bearing outer race out of clutch housing –  First remove seating sleeve for flange shaft seal.

Pressing tapered roller bearing outer race into clutch housing No shim is installed in the clutch housing end.

Pulling off tapered roller bearing inner race –  Before fitting extractor, position thrust plate -40 - 105- on differential cage.   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 Both tapered roller bearing inner races are pressed onto the differential cage in the same way.

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller 46 … 58 mm, e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Fit shim under outer race. –  Support gearbox housing directly below bearing mounting using sleeve -3144-.

Spring pin identification

Dim. „a“ mm	Identification
28.5 (short spring pin) Removing and installing → Fig.	Circumferential groove -arrows-
36.0 (long spring pin), Removing → Fig., Installing → Fig.	No circumferential groove

Allocation of differential cages –  Check hole for spring pin in differential cage. The hole in the differential cage was modified for the longer spring pin.

Hole	Length of spring pin (mm)
-A-	28.5 (short spring pin)
-A- and -B-	36.0 (long spring pin)

Removing and installing spring pin with circumferential groove (short spring 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.

Removing spring pin without circumferential groove (long spring pin): pressing out differential pinion pin When pressed out, spring pin will be sheared off. –  Drive remainder of spring pin out of differential cage.

Installing spring pin without circumferential groove (long spring pin) –  Align hole in differential pinion pin with hole in differential cage. –  Drive in new spring pin with drift -1- until dimension -a- = 3.0 mm. l  The spring pin must not come in contact with gears with differential cage installed.

In some gearboxes, the one-piece thrust washer has a shoulder -A- near the holes In this case, the differential cage has a circumferential groove -B-. –  Lubricate one-piece thrust washer with gear oil and install. –  Install one-piece thrust washer so that it engages in groove -B- in differential cage.

Installing differential bevel gears and differential pinion pin –  Lubricate one-piece thrust washer with gear 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. –  Place threaded pieces -arrows B- in sun gears. Installation position: shoulder to sun gear –  Drive differential pinion pin into final position and secure with spring pin.

Installation position of thrust washer for tapered ring -1-. The shoulder -arrow- points towards spring -B-. Some gearboxes have lugs -A-. Lugs -A- face tapered ring -1-.