SEAT Workshop Service and Repair Manuals

Differential: dismantling and assembling

Special tools and workshop equipment required

t	Gearbox extractor set -U-40100-

t	Gearbox repair set -U-40200-

t	Gearbox repair set -U-40300-

t	Clip extractor with claws -T20022-

t	Electric blower -SAT 1416-

t	Digital thermometer -SAT 4002-

t	The roller bearings and their corresponding outer tracks are matched pairs. They must not be confused or interchanged.

t	The two roller bearings should be replaced together.

t	Adjust the differential whenever the roller bearings, differential casing, gearbox casing or clutch housing are replaced.

1 -	Gearbox casing

2 -

Bolt

3 -	Differential casing

q	If replaced, refer to Adjustment chart → Chapter

4 -	Differential crown

q	Riveted in factory

q	If renewed, the differential crown and the layshaft must be replaced together

q	Removing and fitting → Chapter

5 -	Plate supplement

6 -

Nut

q

70 Nm

7 -

Shim

q	For differential

q	Determine thickness → Anchor

8 -	Outer track, roller bearing

q	Remove → Fig.

q	Fit → Fig.

9 -	Roller bearing

q	Remove → Fig.

q	Fit → Fig.

10 -	Differential assembly

q	Crown riveted in factory

q	If renewed, the differential crown and the layshaft must be replaced together Refer to Adjustment chart → Chapter

q	Drill the rivets and install with bolts → Chapter, Differential crown: removing and installing

11 -	Speedometer mechanism sprocket

q	Remove levering with a flat screwdriver

q	Installing: fit as far as it will go into the differential casing before installing the roller bearing track → Item

12 -	Roller bearing

q	Remove → Fig.

q	Fit → Fig.

13 -	Outer track, roller bearing

q	Remove → Fig.

q	Fit → Fig.

14 -	Clutch housing

15 -

Bush

q	To house the articulation flange oil seal → Item

q	Removing and installing → Fig.

16 -	Articulation flange oil seal

q	Renew → Chapter

17 -	Conical bolt

q

25 Nm

q	Bolt with the threaded device for securing the articulation flanges → Item

18 -	Articulation flanges

q	Removing and fitting → Chapter

19 -	Articulation flange spring

q	Fit behind the articulation flange

20 -	Thrust washer

q	Assembly position: Collar towards the spring, core towards the conical ring

21 -	Conical ring

q	With recess for the thrust washer

q	Assembly position: conical side facing the differential casing

22 -	Safety ring

q	Maintains the position of the conical ring, washer and spring of the articulation flange when dismantled

23 -	Set of thrust washers

q	Impregnate with gearbox oil before installation

24 -	Planet gear

q	Fit → Fig.

25 -	Threaded component to secure the articulation flanges

q	Fit → Fig.

26 -	Satellite shaft

q	Remove with a drift

q	Fit → Fig.

27 -	Elastic pin

q	To hold the satellite shaft

q	Removing and fitting → Fig.

28 -

Satellite

q	Fit → Fig.

29 -	Planet gear

q	Fit → Fig.

Remove the outer track of the roller bearing   Note! t  The procedure and tools needed to remove the outer tracks of the roller bearings are identical for the gearbox and clutch casings. t  To remove the outer track of the clutch casing, previously remove the bush for the articulation flange oilseal → Chapter, Gearbox casing and clutch casing: repairing.

Fit the outer track of the roller bearing   Note! The procedure and tools needed to install the outer tracks of the roller bearings are identical for the gearbox and clutch casings.

Removing the roller bearing   Note! The procedure and tools needed to remove the roller bearings are identical for both sides of the differential box. –  Locate tool -U-40300/13- on the differential. –  Fit extractor -U-40100/1- on -U-40300/13-, making sure the claws are inserted into the notches in the differential casing. Remove the bearing. t  If the bearing cage breaks on extraction, use tool -T20022- to remove the internal bearing ring.

Fitting the roller bearing   Note! t  The procedure and tools needed to remove the roller bearings are identical for both sides of the differential box. t  Before installing the bearing in the differential casing heat to 100 °C with electro-blower -SAT 1416-. The temperature can be checked with digital thermometer -SAT 4002-. –  Install the speedometer actioning sprocket on the satellite carrier side. –  Place tool -U-40300/13- in a press. –  Place differential assembly on tool -U-40300/13-. –  Place tool -U-40300/11- with side B facing the bearing, on the differential assembly.

Removing and fitting satellite shaft elastic pin Removing –  Cover the roller bearing to protect from possible damage and metal filings. –  Remove the pin with a chisel pressing the throat. Installation –  Fit to the differential casing as far as it will go.

Fitting planet gear and satellites –  Coat the thrust washers with gearbox oil and fit in the differential casing. –  Fit the planet gears -A- and secure them with the articulation flanges -B-. –  Insert one satellite and turn 180°. –  Fit the second satellite in the opposite position to the first. –  In this position, turn the satellites to the inside of the differential box by means of the articulation flanges, until they coincide with the holes of the satellite shaft. –  Insert the satellite shaft until it goes through the first satellite. –  Fit the threaded elements securing the articulation flanges, making sure they are correctly seated. –  Fit the satellite shaft to its final position and fit a new elastic pin to secure it.