Volkswagen Workshop Service and Repair Manuals

Differential - disassemble and assemble

Special tools and workshop equipment required

t	Plate -VW 401-

t	Plate -VW 402-

t	Pressure pin -VW 408A-

t	Pressure disc -VW 412-

t	Pressure tube -VW 418A-

t	Pressure tube -VW 454-

t	Fitter -VW 455-

t	Sleeve -VW 472/2-

t	Pressure base -VW 510-

t	Pulling tube -30-14-

t	Tube -2040-

t	Pressure base or 3002 -VW 3002-

t	Lock -3067-

t	Tube -3259-

t	Fitter -3345-

t	Bearing puller -VAG 1582-

t	Pincers -VAG 1582/4-

t	-1-Puller 46 - 56mm or VW 020T - Kukko 21/7-

t	-4-Auxiliary support -KUKKO 22/2 -

t	Pressure base or VW 062 -30-205-

t	Supporting tube -40-21-

t	Torque wrench - 5 to 50Nm (enc. 1/2") -VAG 1331-

t	Pincers -VAG 1582/3-

Note t  Heat inside bearing on the tapered roller bearing to 100 °C before installing. t  Always change both tapered roller bearings as a set. t  Adjust the differential when replacing the tapered roller bearings, differential case, transmission case or clutch case → Chapter.

1 -	Tapered screw

q

25 Nm

q	Fasten on the threaded part → Item

2 -	Right propelling flange

q	Do not invert. The right and left propelling flanges are different.

3 -	Pressure spring for propelling flange.

q	Installed behind the propelling flange

4 -	Sealing washer

q	Installation position: lip facing the pressure spring

5 -	Tapered ring

q	Installation position: shoulder facing the differential case

6 -

Circlip

q	Keeps the tapered ring, sealing washer and spring in position when the propelling flange is removed

7 -	Planetary gear

q	Installation → Fig.

8 -	Flanged shaft nut

q	Installation → Fig.

9 -	Satellite shaft

q	To remove, cut the elastic pin → Item

q	Installation → Fig.

10 -

Satellite

q	Installation → Fig.

11 -	Stop cover for satellite gears

q	Install lubricated with transmission oil

12 -	Left propelling flange

q	With retainer plate

q	Do not invert. The right and left propelling flanges are different.

13 -	Retainer for the left propelling flange

q	Left and side diameters are different

q	Replace → Chapter

14 -	Adjustment shim S1

q	For the differential

q	Always with 1 mm thickness

15 -	Outside ring on the tapered roller bearing

q	Removal → Fig.

q	Installation → Fig.

16 -	Tapered roller bearing

q	Removal → Fig.

q	Installation → Fig.

17 -	Differential box

q	With riveted differential master gear

q	If replacement is required, the pinion shaft must also be replaced → Item.

18 -	Elastic pin

q	To fasten satellite shaft

19 -	Tapered roller bearing

q	Removal → Fig.

q	Installation → Fig.

20 -	Outside ring on the tapered roller bearing

q	Removal → Fig.

q	Installation → Fig.

21 -	Adjustment shim S2

q	For the differential

q	Determine thickness → Chapter

22 -	Retainer for the right propelling flange

q	Left and side diameters are different

q	Replace → Chapter

23 -	Transmission case

24 -	Clutch case

Removing the outside ring on the tapered roller bearing of the transmission case A -  Auxiliary support -KUKKO 22/2- B -  Puller 46 - 56mm or VW 020T -Kukko 21/7-

Installing the outside ring of the tapered roller bearing on the transmission case –  Install adjustment shim S1, always with 1-mm thickness, below the outside ring. –  Support the transmission case by placing the Tube -3259- directly below the bearing support.

Removing the outside ring on the tapered roller bearing -A- of the clutch case –  Use Puller 46 - 56mm or VW 020T -Kukko 21/7--B- to remove the outside ring from the tapered roller bearing.   Note Remove the Speed sensor -G22- before removing the outside ring from the tapered roller bearing.

Installing the outside ring on the tapered roller bearing of the clutch case –  Support the clutch case by placing the Fitter -3345- directly below the bearing support. –  Install the Speed sensor -G22- after installing the outside ring of the bearing.

Removing the inside ring from the tapered roller bearings –  Before installing the puller, install the Sleeve - VW 472/2--VW 472/2- and the Pressure base or VW 3002 -3002- on the differential case.   Note The internal tracks on both bearings are removed in an identical way as for the differential case.

Installing the inside ring on the tapered roller bearings –  Support the opposite side of inside ring with the Fitter -VW 455-.

Removing the satellite shaft Cut the elastic pin to remove the shaft. –  Remove the elastic pin remains from the differential case.

Installing the planetary and satellite gears –  Lubricate the stop cover of the satellite gears with transmission oil. –  Install the two planetary gears and lock them (for example, with the propelling flange). –  Install the satellite gears displaced by 180° each other. –  Install the satellite shaft -arrow A- to the first satellite. –  Install nuts -arrows B- on the planetary gears. Installation position: edge facing the planetary gear. –  Install the satellite shaft to the stop and fasten it with the elastic pin.

Removing the inside ring from the tapered roller bearing –  Before mounting the pulling device, place the Sleeve -VW 472/2- and the Pressure base or VW 3002 -3002- in the planetary gear box.

Installing the inside ring on the tapered roller bearing –  Support the inside ring on the opposite side with the Fitter -VW 455-.