Volkswagen Workshop Service and Repair Manuals

Four-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 411-

t	Press tool -VW 412-

t	Drift sleeve -30 - 23-

t	Thrust plate -40-105-

t	Thrust plate -3005-

t	Tube -3259-

t	Tube -3296-

t	Assembly tool -3301-

t	Tube -3345-

t	Internal puller -1 - Kukko 21/7-

t	Puller -2 - Kukko 18/1-

t	Splitter -3 - Kukko 17/1-

t	Counter support -4 - Kukko 22/2-

t  Puller -Kukko 204/2-

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

6 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	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 -

Seal

q	Between gearbox and bevel box.

q	Renewing → Chapter

q	Pull out with oil seal extractor lever -VW 681- or extractor tool -T20143/2-.

q	With gearbox dismantled, can be driven in to stop with thrust piece -T40007-.

11 -

Seal

q	For right flange shaft

q	Left and right diameters differ

q	Renewing with manual gearbox with bevel box installed → Chapter

12 -	Hexagon bolt  → Item

13 -	Countersunk bolt, 33 Nm

q	Screw into threaded piece → Item

14 -	Right flange shaft

q	Removing and installing → Chapter

15 -

Seal

q	Remove to renew polygon needle bearing → Item

16 -	Needle bearing (polygon bearing)

q	Renewing → Chapter

17 -	Retaining ring

q	Always renew

18 -

Bevel box

q	Seals, flange shaft mounting and output flange mounting → Chapter

19 -

Seal

q	Between bevel box and gearbox

q	Replacing with bevel box removed → Chapter

20 -	Large differential bevel gear

q	Installing → Fig.

21 -	Differential pinion pin

q	Removing → Fig.

q	Installing → Fig.

22 -	Spring pin

q	For securing differential pinion pin

q	Removing → Fig.

q	Driving in new spring pin flush → Fig.

23 -	Small differential bevel gear

q	Removing and installing → Fig.

24 -	Threaded piece

q	Installing → Fig.

25 -	One-piece thrust washer

q	Coat with gear oil when installing

26 -	Retaining ring

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

27 -	Tapered ring

q	With grooves to engage in thrust washer

q	Installation position: taper towards differential cage

28 -	Thrust washer

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

29 -	Compression spring for left flange shaft

q	Installed behind left flange shaft

30 -	Left flange shaft

31 -

Seal

q	For left flange shaft

q	Left and right diameters differ

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- –  Clamp internal puller -B- between tapered roller bearing outer race and washer.   Note After pulling out, check washer for damage and renew if necessary.

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 –  Place thrust plate -40-105- on differential cage. –  Clamp puller, e.g. -Kukko 204/2- in vicinity of flat sides of differential cage behind inner race.   Note When pulling off inner race, ensure that hooks do not bend outwards, further tightening bolt -arrow- if necessary.

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-

Pressing on tapered roller bearing inner race –  Set sleeve -3301/3- from assembly tool -3301- with notch -arrow- (larger inner diameter) on tapered roller bearing inner race.

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 differential pinion pin and spring pin for differential pinion pin –  First drive spring pin -1- flush into differential pinion pin -2-. –  Set differential under press with spring pin -arrow- facing extension -30 - 23-. –  Now press differential pinion pin out.   Note If necessary, removed sheared-off parts of spring pin from differential cage.

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 → Fig..

Installing spring pin –  Drive in new spring pin -arrow- flush to differential cage using a drift -1-.