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-

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 -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 races   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 installing 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 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 both 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.