SEAT Workshop Service and Repair Manuals

Differential: dismantling and assembly

Special tools and workshop equipment required

t	Gearbox extractor set -U-40100-

t	Gearbox repair set -U-40200-

t	Clip extractor with claws -T20022-

t	Electric blower -SAT 1416-

t	Digital thermometer -SAT 4002-

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 thickness

3 -	Outer track, roller bearing

q	Remove → Fig.

q	Fit → Fig.

4 -	Roller bearing

q	Remove → Fig.

q	Fit → Fig.

5 -	Differential crown

q	Removing and fitting → 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	Fit → Fig.

8 -	Component to secure the aticulation flange

9 -

Satellite

q	Fit → Fig.

10 -	Satellite shaft

q	Remove with a drift

11 -	Speedometer gear

q	Remove levering with a screwdriver

12 -	Roller bearing

q	Remove → Fig.

q	Fit → Fig.

13 -	Outer track, roller bearing

q	Remove → Fig.

q	Fit → Fig.

14 -

Shim S2

q	For differential

q	etermine 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 -	Elastic 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 → Fig.

q	Fit the crown wheel with bolts → Fig.

20 -

Nut

q

70 Nm

21 -	Differential crown wheel, rivetted or bolted

q	Rivetted on the production line

q	Bolt assembly → Fig.

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.

Fit 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 bearing. –  Fit extractor -U-40100/1- on -U-40200/4-, 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! The procedure and tools needed to remove the roller bearings are identical for both sides of the differential box –  Heat the roller bearing to 100° with the -SAT 1416 -electric blower before fitting. –  Fit the speedometer actioning gear. –  Place tool -U-40200/19- (side B) over the bearing and fit.

Fitting planet gear and satellites –  Coat the thrust washers with gearbox oil and fit in the differential box. –  Fit the planet gears -A- and secure 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 components making sure they are correctly seated. –  Fit the satellite shaft to its final position and fit the elastic pin to secure it.

Drilling the rivet heads   Note! t  Protect the roller bearings and gear for speedometer actioning from damage and metal filings t  Before and after drilling the rivets, thoroughly clean the differential casing –  Drill the rivet heads, on the opposite side to the speedometer gear, with a 12 mm drill bit Ø. –  Remove the rivets from their holes with a drift.

Securing the differential crown wheel to the differential casing The removed rivets will be replaced with special bolts, nuts and locking tabs. → Refer to ”Parts Catalogue”.