SEAT Workshop Service and Repair Manuals

Differential: dismounting and assembling

t	The differential must be adjusted whenever the tapered roller bearings are replaced. Consult the Adjustments Chart → Chapter.

t	The tapered roller bearings must always be replaced together.

t	The tapered roller bearings and their corresponding outer tracks come in pairs. Do not mix them up or exchange them with other bearings.

Assembly chart

1 -	Gearbox casing

2 -

Bolt

3 -	Differential box

q	In the event of replacement, consult the Adjustments Chart → Chapter.

4 -	Crown for the riveted differential

q	Factory riveted

q	Assembly with bolts → Chapter

q	In the event of replacement, the crown of the differential and the secondary shaft must be replaced together.

q	Dismounting and assembly → Chapter, Crown of the differential: dismounting and assembling

5 -	Plate washer

6 -	Nut, 70 Nm

7 -	Adjustment washer

q	Determine the thickness →

8 -	Outer track, tapered roller bearing

q	Dismount → Fig.

q	Assemble → Fig.

9 -	Tapered roller bearing

q	Dismount → Fig.

q	Assemble → Fig.

10 -	Differential unit

q	In the event of replacement, the crown of the differential and the secondary shaft must be replaced together. Consult the Adjustments Chart → Chapter.

q	Factory riveted crown.

q	Drilling of the rivets and assembly with bolts → Chapter

11 -	Pinion for working the speedometer

q	Dismount it by levering with a flat screwdriver.

q	Assembly: fit it in up to the top in the differential box before assembling the tapered roller bearing → Item.

12 -	Tapered roller bearing

q	Dismount → Fig.

q	Assemble → Fig.

13 -	Outer track, tapered roller bearing

q	Dismount → Fig.

q	Assemble → Fig.

14 -	Clutch casing

15 -

Bush

q	Retainer for the coupling flange

q	Dismount and assemble → Chapter

16 -	Retainer for the coupling flange

q	Replace → Chapter

17 -	Bolt, 25 Nm

q	Screw in with the threaded part for attaching the coupling flanges → Item.

18 -	Coupling flanges

q	Dismount and assemble → Chapter

19 -	Spring for coupling flange

q	Assemble it behind the coupling flange.

20 -	Front washer

q	Position for assembly: Collar facing towards the spring, core facing towards the tapered ring.

21 -	Tapered ring

q	With trimmings for fitting the front washer

q	Position for assembly: tapered side facing towards the differential box.

22 -	Safety ring

q	Keeps the tapered ring, the washer and the spring for the coupling flange in position when the latter is dismounted.

23 -	Set of friction washers

q	Coat them with gearbox oil before assembling them.

24 -	Differential side gear

q	Assemble → Fig.

25 -	Threaded part for attaching the coupling flanges

q	Assemble → Fig.

26 -	Axle for satellites

q	Dismount it by striking with a punch.

27 -	Elastic linchpin

q	Dismount it by striking with a suitable punch.

q	Assemble ⇒ Fit it up to the stop.

28 -

Satellite

q	Assemble → Fig.

29 -	Differential side gear

q	Assemble → Fig.

Special tools and workshop equipment required

t	Case of tools for repairing gearboxes -U-40200-

t	Case of tools for repairing gearboxes -U-40300-

t	Pincer extractor tool with grippers -T20022-

Dismount the outer track of the tapered roller bearing   Note! The procedure and the tools needed for dismounting the outer tracks of the tapered roller bearings are the same in the gearbox casing and in the clutch casing. –  Extract the outer track of the tapered roller bearing from the gearbox casing with tool -U-40200/10- and -U-40300/14-.

Assemble the outer track for the tapered roller bearing   Note! The procedure and the tools needed for assembling the outer tracks for the tapered roller bearings are the same as for the gearbox casing and the clutch casing. –  Assemble the outer track for the tapered roller bearing in the clutch casing using tool -U-40200/10- and tool -U-40300/12-.

Dismount the tapered roller bearing –  Place tool -U-40300/13- on the differential. –  Place the extractor tool -U-40100/1- over the -U-40300/13- trying to ensure that the grippers are inserted in the notches that are located in the differential box. –  Extract the bearing. t  If the bearing holder is broken during the extraction process, use tool -T20022- for extracting the inner ring from the bearing.

Assemble the tapered roller bearing   Note! Before assembling the bearing in the differential box, heat it to approximately 100º with the electrical blower -SAT 1416-. The temperature may be checked with the digital thermometer -SAT 4002-. The procedure and the tools needed for assembling the tapered roller bearings are the same on both sides of the differential box. –  Assemble the pinion for working the speedometer. –  Place the tool -U-40300/13- into a press. –  Place the differential unit over the tool-U-40300/13-. –  Place the tool -U-40300/11- with side B facing towards the bearing, over the differential unit. –  Work the press until the tapered roller bearing is mounted in its position.

Assemble sun gears and planetary gears –  Impregnate the friction washers with gear oil and assemble in the differential housing. –  Fit the differential side gears -A- and attach them with the coupled flanges -B-. –  Introduce a planetary gear and turn it 180°. –  Place a second planetary gear opposite the first. –  In this position, turn the planetary gears towards the inside of the differential housing by means of the coupled flanges until they coincide with the holes in the planetary gear shaft. –  Insert the planetary gear shaft until it goes through the first planetary gear. –  Assemble the threaded parts to secure the coupled flanges and completely insert the planetary gear shaft right to its final position. –  Attach the spring pin to secure the planetary gear shaft.