Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 391 Drive shaft fitting appliance
• ◆ VW 681 Oil seal extractor
• ◆ 3109 Puller
• ◆ 3155 Ring nut spanner
• ◆ 3319 Thrust piece

• ◆ If taper roller bearings are to be re-used, mark the adjusting ring => Fig.2
• ◆ The drive pinion does not need to be removed for removing and installing the differential.

• Gearbox housing
• Speedometer drive
• ◆ With marking for oil level indication => Fig.4
• Output shaft/drive flange
• ◆ Install thread facing drive flange
• ◆ Remove before taking out differential
• ◆ First adjust differential before installing
• O-ring
• ◆ Always replace

• Adjusting ring
• ◆ Removing => Fig.3
• ◆ If used bearings are re-inserted, mark installation position and position on marking again when installing
  => Fig.2
• ◆ When installing new bearing, pay attention to setting instructions =>Adjusting differential, Page 39-63
• Oil seal for drive flange
• ◆ Before installing, pack space between sealing lips with multi-purpose grease
• ◆ Can be renewed with gearbox installed
  
• ◆ Remove with VW 681
• ◆ Driving in => Fig.1
• Taper ring
• ◆ Shoulder faces thrust washer
• Thrust washer
• ◆ Place over compression spring
• Compression spring

• Drive flange
• ◆ Insert with taper ring, thrust washer and compression spring
• ◆ Remove before taking out inner circlip on bevel gear
• ◆ Removing and installing => Fig.7
• Dished washer
• Circlip
• Cover
• Locking element
• Screw, 12 Nm
• Cover
• Circlip
• Dished washer
• Drive flange
• ◆ Insert with taper ring, thrust washer and compression spring
• ◆ Remove before taking out inner circlip on bevel gear
• ◆ Removing and installing => Fig.7

• Compression spring
• Thrust washer
• ◆ Place over compression spring
• Taper ring
• ◆ Shoulder faces thrust washer
• Oil seal for drive flange
• ◆ Before installing, pack space between sealing lips with multi-purpose grease
• ◆ Can be renewed with gearbox installed
  
• ◆ Remove with VW 681
• ◆ Driving in => Fig.1
• Bearing body, 150 Nm
• ◆ Remove with 3155
• ◆ Installing => Fig.5
• O-ring
• ◆ Always replace

• Output shaft/drive flange
• ◆ Install thread facing drive flange
• ◆ Before removing, take out differential
• ◆ First adjust differential before installing
• Differential
• ◆ Dismantling and assembling
• ◆ Before removing differential, take out bearing body, adjusting ring and output shafts
• Screw, 12 Nm
• Locking element

After adjusting taper roller bearings, secure bearing body and adjusting ring.

• Circlip
• ◆ First remove drive flange before removing circlip
• ◆ Removing and installing => Fig.6

• Circlip
• ◆ First remove drive flange before removing circlip
• ◆ Removing and installing => Fig.6
• Seal
• ◆ Always replace
• Cover
• ◆ For differential
• Screw, 28 Nm
• ◆ Insert with locking fluid
  AMV 185 101 A1

→ Fig.1     Driving in drive flange oil seal up to stop

→ Fig.2     Marking adjusting ring

• ‒ If used bearings are re-inserted, mark installation position (arrow) and again position on marking when installing.

→ Fig.3     Removing adjusting ring

→ Fig.4     Speedometer drive

• ‒ With gearbox installed, check gear oil in final drive .

→ Fig.5     Inserting differential and screwing in bearing body as far as stop to 150 Nm

→ Fig.6     Inserting circlip (arrow)

• ‒ Remove circlip with two screwdrivers.

→ Fig.7     Removing and installing drive flange

Removing

• ‒ Mount puller 3109 and remove circlip.
• ‒ Pull off drive flange with VW 391.

Installing

• ‒ Insert drive flange, dished washer and circlip.
• ‒ Pull drive flange in with 3109.

Drive flange can also be pulled in with VW 391.

On vehicles with triple roller drive shafts:

• ‒ Bolt puller Kukko 18-0 using two 8x35 mm bolts and 8 mm ø washers to flange.
• ‒ Pull off drive flange.