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	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, differential casing, gearbox casing or clutch housing are replaced → Chapter

1 -

Bolt

q

25 Nm

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

2 -	Articulation flange

q	Removing and fitting → Chapter

3 -	Articulation flange spring

q	Fit behind the articulation flange

4 -	Thrust washer

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

5 -	Conical ring

q	With recess for the thrust washer

q	Assembly position: conical side facing the differential casing

6 -	Safety ring

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

7 -	Gearbox casing

8 -	Set of thrust washers

q	Fit with gear oil

9 -	Planet gear

q	Fit → Fig.

10 -	Threaded component to secure the articulation flanges

q	Fit → Fig.

11 -	Satellite shaft

q	Remove with a drift

q	Fit → Fig.

12 -	Securing pin

q	To hold the satellite shaft

q

Renew

q	Removing and installing → Fig.

13 -

Satellite

q	Fit → Fig.

14 -

Rivet

q	Only for factory production

q	Drill → Chapter, Differential crown: removing and installing

15 -

Shim S2

q	Always 1 mm thick

16 -	Outer track, roller bearing

q	Remove → Fig.; first remove the bush → Item

q	Fit → Fig.

17 -	Roller bearing

q	Remove → Fig.

q	Fit → Fig.

18 -	Clutch housing

19 -	Repair kit

q	Only for post-sale service

q	Bolt assembly → Chapter, Differential crown: removing and installing

q	Hexagon nut, 65 Nm

20 -	Differential crown

q	Rivetted in the factory

q	A matched pair with the layshaft, if it needs replacing they must both be replaced

q	Removing and fitting → Chapter

21 -	Differential casing

22 -	Outer track, roller bearing

q	Remove → Fig.

q	Fit → Fig.

23 -

Shim S1

q	Determine thickness → Chapter, Differential: adjustment

24 -	Articulation flange oilseal

q	Renew → Chapter

25 -

Bush

q	To house the articulation flange oilseal

q	Removing and fitting → Chapter, Clutch housing: repairing

Remove the outer track of the clutch housing roller bearing

Remove the outer track of the clutch housing roller bearing

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 °C with the -SAT 1416- electric blower before fitting. The temperature can be measured with the -SAT 4002- digital thermometer. –  Place tool -U-40200/18- over the bearing and fit it.

Remove the outer track of the clutch housing roller bearing

Fitting the outer track of the clutch housing roller bearing

Removing and fitting satellite shaft securing pin Removing –  Cover the roller bearing to protect from possible damage and metal filings. –  Remove the pin with a drift 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 and secure them with the articulation flanges. –  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 -A- until it goes through the first satellite. –  Fit the threaded elements -B- securing the articulation flanges, making sure they are correctly seated. –  Fit the satellite shaft to its final position and fit the elastic pin to secure it.