Volkswagen Workshop Service and Repair Manuals

Front-wheel drive - dismantling and assembling differential

Special tools and workshop equipment required

t	Pressure plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Thrust plate -40-105-

t	Thrust plate -3005-

t	Only gearboxes with right stub shaft

t	Thrust piece -VW 473-

t  Only gearboxes with right flange shaft

t  Tube -VW 415 A-

t	Tube -3259-

t	Tube -3296-

t	Tube -3345-

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

t	Adapter -V.A.G 1582/6A-

t	-1-Internal puller -Kukko 21/7-

t	-2-Puller -Kukko 18/1-

t	-3-Splitter -Kukko 17/1-

t	-4-Counter support -Kukko 22/2-

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 is renewed, adjust differential → Chapter.

1 -	Gearbox housing

2 -

Shim

q	For differential

q	Determining thickness → Chapter

3 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

5 -	Differential cage

q	With riveted final drive gear

q	Support -arrow- for right tapered roller bearing 12.5 mm longer beginning with introduction of right flange shaft.

Allocation → Electronic parts catalogue „ETKA“

6 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Gearbox with right stub shaft: pressing on → Fig.

q	Gearbox with right flange shaft: pressing on → Fig.

7 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

8 -

Washer

Installation position: shoulder on inner circumference faces clutch housing

Allocation → Electronic parts catalogue „ETKA“

9 -	Clutch housing

10 -

O-ring

q	Always renew

11 -	Protective ring

q	Can be pulled off or pushed onto stub shaft → Item by hand

12 -	Countersunk bolt, 33 Nm

q	Screw into threaded piece → Item

13 -	Stub shaft

q	From gearbox date 01 11 4, replaced with a flange shaft → Item

Allocation → Electronic parts catalogue „ETKA“

14 -

Seal

q	Through gearbox date 31 10 4, for stub shaft

q	Renewing with gearbox installed → Chapter

15 -	Right flange shaft

q	Replaces stub shaft from gearbox date 01 11 4 → Item

Allocation → Electronic parts catalogue „ETKA“

16 -	Protective ring

q	Pry protective ring off flange shaft with a screwdriver, alternating sides → Item

q	Push on protective ring to stop by hand

q	Protective ring must engage in flange shaft

17 -

Seal

q	For flange shaft from gearbox date 01 11 4 → Item

q	Renewing with gearbox installed → Chapter

Allocation → Electronic parts catalogue „ETKA“

18 -	Compression spring for flange shaft or stub shaft

q	Installed behind flange shaft or stub shaft

19 -	Thrust washer

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

20 -	Tapered ring

q	Installation position: taper towards differential cage

21 -	Retaining ring

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

22 -	Large differential bevel gear

q	Installing → Fig.

23 -	Differential pinion pin

q	Drive out using drift

q	Installing → Fig.

24 -	Spring pin

q	For securing differential pinion pin

q	Removing and installing → Fig.

25 -	Small differential bevel gear

q	Removing and installing → Fig.

26 -	Threaded piece

q	Installing → Fig.

27 -	One-piece thrust washer

q	Coat with gear oil when installing

28 -	Protective ring

q	Pry off protective ring using screwdriver on alternate sides

q	Install with indentation facing away from threaded hole in flange shaft

q	Push on protective ring to stop by hand

q	Protective ring must engage in flange shaft

29 -	Flange shaft

30 -

Seal

q	For flange shaft

Allocation → Electronic parts catalogue „ETKA“

q	Renewing with gearbox installed → Chapter.

Pulling tapered roller bearing outer race out of clutch housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46 … 58 mm, e.g. -Kukko 21/7-   Note After pulling out, renew washer.

Press tapered roller bearing outer race with washer into clutch housing   Note t  Observe installation position of washer. t  Shoulder on inner circumference faces seal in clutch housing.

Pulling off tapered roller bearing inner race –  Before setting up pulling device, set thrust plate -40-105- on differential housing.

Pressing on tapered roller bearing inner race

Pulling off tapered roller bearing inner race A -  Puller, e.g. -Kukko 18/1- B -  Splitter, 12 … 75 mm, e.g. -Kukko 17/1-

Gearbox with right stub shaft: pressing on tapered roller bearing inner race –  Set smaller outer diameter of press tool -VW 473- on tapered roller bearing inner race. Cage with tapered rollers must be easy to turn during pressing.

Gearbox with right flange shaft: pressing on tapered roller bearing inner race Cage with tapered rollers must be easy to turn during pressing.

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 –  Support gearbox housing with tube -3345- directly below bearing support.

Removing and installing spring pin for differential pinion pin Removing –  Cover tapered roller bearing inner race to prevent 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.

Installing differential bevel gears –  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.