SEAT Workshop Service and Repair Manuals

Differential: dismantling and assembling

Special tools and workshop equipment required

t	Electric blower -SAT 1416-

t	Digital thermometer -SAT 4002-

t	Kit -T20022-

t	Kit -T20140-

t	Kit -U-40100-

t	Kit -U-40200A-

t	Heat the inner roller bearing track to 100 °C before fitting.

t	The two roller bearings should be replaced together.

t	Adjust the differential whenever the roller bearings are replaced → Chapter.

1 -	Gearbox casing

2 -

Shim S1

q	For differential

q	Always 1 mm thick

3 -	Outer track, roller bearing

q	Remove → Fig.

q	Fitting → Fig.

4 -	Roller bearings

q	Remove → Fig.

q	Fitting → Fig.

5 -	Differential crown

q	Removing and installing → Chapter

q	Install: refer to section Code letters, group numbers, ratios, filling quantities → Chapter

6 -	Set of thrust washers

q	Fit with gear oil

7 -	Planet gear

q	Fitting → Fig.

8 -	Threaded component

q	To secure flanged shaft oil seals

9 -

Satellite

q	Fitting → Fig.

10 -	Satellite shaft

q	Remove with a drift

11 -	Speedometer gear

q	Remove levering with a screwdriver

12 -	Roller bearings

q	Remove → Fig.

q	Fitting → Fig.

13 -	Outer track, roller bearing

q	Remove → Fig.

q	Fitting → Fig.

14 -

Shim S2

q	For differential

q	Determine thickness → Chapter

15 -	Clutch housing

16 -

Bracket

q	Secure the satellite shaft in the gearbox with the rivetted crown wheel

q	It is secured with the rivets of the diffferential crown wheel → Item

17 -

Split pin

q	Fit to the centre of the shaft

18 -	Differential casing

q	If replaced, refer to Adjustment chart → Chapter

19 -

Rivet

q	Only for production

q	Drill → Chapter

q	Fit the crown wheel with bolts → Chapter

20 -

20 Nm

21 -	Differential crown wheel, rivetted or bolted

q	Riveted in the factory

q	Bolt assembly → Chapter

Remove the outer track of the roller bearing   Note! The procedure and tools needed to remove the outer tracks of the roller bearings are identical for the gearbox and clutch casings. –  Remove the outer roller bearing track from the clutch housing, with kit -T20140-. –  Procedure for extracting the outer track → Anchor.

Fitting the outer track of the roller bearing   Note! The procedure and tools needed to remove 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-40200/4- on the differential. –  Fit extractor -U-40100/1- on tool -U-40200/4-, making sure the claws are inserted into the notches in the differential casing. Remove the bearing. If the bearing cage breaks on extraction, use tool -T20022- to remove the internal bearing ring.

Fitting the roller bearing   Note! The procedure and tools needed to fit the roller bearings are identical for both sides of the differential casing. –  Heat the roller bearing to 100 °C with the -SAT 1416- electric blower before fitting. Check the temperature with thet -SAT 4002- digital thermometer. –  Fit the speedometer actioning gear. –  Place tool -U-40200/19- -side B- over the bearing and fit it.

Fitting planet gears and satellites –  Coat the thrust washers with gearbox oil and fit in the differential casing. –  Fit the planet gears -A- and secure with the flanged shafts -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 casing by means of the flanged shafts, until they coincide with the holes of the satellite shaft. –  Insert the satellite shaft until it goes through the first satellite. –  Fit the threaded components making sure they are correctly seated. –  Fit the satellite shaft to its final position and fit the circlip to secure it.