Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Tube -VW 418 A-

t	Thrust piece -VW 454-

t	Installing sleeve -VW 455-

t	Spacer sleeve -VW 472/2-

t	Thrust pad -VW 510-

t	Tube -30 - 14-

t	Tube -2040-

t	Thrust piece -3002-

t	Counterhold -3067-

t	Tube -3259-

t	Wheel bearing tube -3345-

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

t	Adapter -V.A.G 1582/4-

t	Internal puller -1 - Kukko 21/7-

t	Counter support -4 - Kukko 22/2-

t	Thrust plate -30 - 205-

t	Drift sleeve -40 - 21-

t	Torque wrench -V.A.G 1331- (5 ... 50 Nm)

t	Adapter -V.A.G 1582/3-

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 -	Countersunk bolt, 25 Nm

q	Screw into threaded piece → Item

2 -	Right flange shaft

3 -	Compression spring for flange shaft

q	Installed behind flange shafts

4 -	Thrust washer

q	Installation position: shoulder towards spring

5 -	Tapered ring

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 -

Sun wheel

q	Installing → Fig.

8 -	Threaded piece

q	Installing → Fig.

9 -	Differential pinion pin

q	To remove, shear off spring pin → Item → Fig.

q	Installing → Fig.

10 -	Planet pinion

q	Installing → Fig.

11 -	One-piece thrust washer

q	Coat with gear oil when installing

12 -	Left flange shaft

13 -	Oil seal for left flange shaft

q	Renewing with manual gearbox installed → Chapter.

14 -

Shim S1

q	For differential

q	Always 1 mm thick

q	Shim S1 discontinued as of gearbox date 04 12 6 → Fig.

q	Bearing seat for tapered roller bearing outer race adapted in gearbox housing

q	Allocation → Electronic parts catalogue (ETKA)

15 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

16 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

17 -	Differential cage

q	With final drive gear

18 -	Spring pin

q	For securing planet pinion pin

q	Will be sheared off when removed → Fig.

19 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

20 -	Tapered roller bearing outer race

q	Pressing out → Fig.

q	Pressing in → Fig.

21 -

Shim S2

q	For differential

q	Determining thickness → Chapter

22 -	Oil seal for right flange shaft

q	Renewing with manual gearbox installed → Chapter.

23 -	Gearbox housing

q	Repairing → Chapter

q	Shim S1 discontinued as of gearbox date 04 12 6 → Fig.

q	Bearing seat for tapered roller bearing outer race adapted

q	Allocation → Electronic parts catalogue (ETKA)

24 -	Clutch housing

q	Repairing → Chapter

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 –  Check whether a shim S1 has to be placed under the outer race → Fig. –  Fit a 1 mm thick shim S1 under outer race as necessary. –  Support gearbox housing with tube -3259- directly below bearing support.

Pulling off tapered roller bearing inner races   Note Both tapered roller bearing inner races are pulled off the differential cage in the same way.

Pressing on tapered roller bearing inner race   WARNING Wear protective gloves! –  Heat inner tapered roller bearing race to approx. 100 °C before pressing on. –  Support inner race on opposite side using installing sleeve -VW 455-. Shoulder of sleeve -VW 455- faces towards differential cage.

Pressing tapered roller bearing outer race -A- out of clutch housing B -  Internal puller, 46 … 58 mm, e.g. -Kukko 21/7- –  Clamp internal puller securely behind tapered roller bearing outer race.

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with wheel bearing tube -3345- directly below bearing mounting.

Pulling off tapered roller bearing inner race –  Before fitting extractor, position spacer sleeve -VW 472/2- and thrust piece -3002- on differential housing.

Pressing on tapered roller bearing inner race   WARNING Wear protective gloves! –  Heat inner tapered roller bearing race to approx. 100 °C before pressing on.

Pressing out differential pinion pin When pressed out, spring pin will be sheared off. –  Drive remainder of spring pin out of differential housing.

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. –  Drive differential pinion pin into final position and secure with spring pin.