SEAT Workshop Service and Repair Manuals

Differential: dismantling and assembling

Special tools and workshop equipment required

t	Extractor -T20022-

t	Tool to fit interior tracks in the differential -T20100-

t	Interior extractor with striker (2 legs) -T20004-

t	Case -U-40200-

t	Case -U-40100-

t	Case -U-40450A-

t	Before fitting the interior rings of the conic roller bearings, heat to 100º C.

t	If necessary, replace the two conic roller bearings of the differential as a set.

1 -	Gearbox housing

2 -	Adjustment washer

q	For the differential

q	Determine the thickness → Chapter

3 -	Exterior ring of the conic roller bearing

q	Extracting → Fig.

q	Fitting → Fig.

4 -	Interior ring of the conic roller bearing

q	Extracting → Fig.

q	Fitting → Fig.

5 -	Differential housing

q	The pinion for controlling the half-shafts is bolted to the differential housing

6 -	Control pinion of the speedometer

q	Fit to the stop in the differential housing before fitting the interior ring of the bearing

7 -	Interior ring of the conic roller bearing

q	Extracting → Fig.

q	Fitting → Fig.

8 -	Exterior ring of the conic roller bearing

q	Extracting → Fig.

q	Fitting → Fig.

9 -	Clutch housing

10 -

Seal

q	Replace → Chapter

11 -	Outlet shaft

q	Removing and refitting → Chapter

12 -	Protection plate

q	For the gear change outlet shaft

q	Removing → Fig.

q	Fitting → Fig.

13 -	Safety ring

q	Always replace

14 -	Set of drive washers

q	Fit with gear oil

15 -

Sun gear

q	Fitting → Fig.

16 -

Satellite

q	Fitting → Fig.

17 -	Safety ring

q

Replace

18 -	Satellite shaft

q	The shaft has different diameters. The front with the centring hole -arrow- has a smaller diameter

q	Removing → Fig.

q	Fitting → Fig.

19 -	Pinion for half-shaft control

q	This is twinned with the pinion of the secondary shaft and if replaced, the two must be replaced as a set

q	Removing → Fig.

q	Fitting position: the chamfered side of the threaded holes for the fitting bolts lies facing the differential housing

20 -	Differential housing

21 -	Hexagonal bolt, 80 Nm

q	These must be replaced when removed

Release the interior rings of the conic roller bearings The interior rings of both conic roller bearings in the differential housing are extracted in the same way.

Fitting the interior rings of the conic roller bearings –  Place the differential housing in a press using the tool -T20100-, side A. The interior rings of both conic roller bearings in the differential housing are fitted in the same way.

Removing the exterior ring/conic roller bearing from the clutch and gearbox housing The exterior rings of the clutch and gearbox housings are extracted in the same way. To extract the exterior ring/conic roller bearing from the gearbox housing, a second mechanic is needed to hold the housing while the operation is undertaken.

Fitting the exterior ring/conic roller bearing from the clutch and gearbox housing The exterior rings of the clutch and gearbox housings are fitted in the same way. To fit the exterior ring/conic roller bearing from the gearbox housing, a second mechanic is needed to hold the housing while the operation is undertaken.

Removing the protection plate from the outlet shaft –  Place the outlet shaft in a press using the tool -U-40100/4-. –  Carry out the operation taking care not to damage the protection plate.

Fitting the outlet shaft protection plate –  Place the outlet shaft in a press using the tool -T20100-, side B.

Removing the satellite shaft –  Remove the safety rings from the satellite shaft. Removal procedure: –  Fix the differential housing in a vice protected with jaws. –  Remove the satellite shaft by hitting with a pole from the side of the smallest diameter (marked with a dot).

Fitting the satellite shaft –  Fit the whole set of drive washers lubricated with gearbox oil. –  Place the differential in a vice protected with jaws. –  Insert the satellite shaft in the differential housing by the side with the smallest diameter (identified by a hole at the end). –  Fit the satellites to the shaft. –  Fit the satellite shaft to the end position by hitting with a pole, and fix with new safety rings.

Fitting the sun gear –  Place the unhung sun gears at 180° to each other and slide inside the differential housing -arrow-.

Removing the pinion for the half-shaft control –  Remove the hexagonal bolts holding the half-shaft control pinion to the differential housing. –  Place the pinion in the tool -U-40450A/1-. –  Use the tool -T20100- side A in a press.