SEAT Workshop Service and Repair Manuals

Differential: assembly and disassembly Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Hot air blower -SAT 1416-, see equivalent → Anchor

t	Kit (case) -T20022-, see equivalent → Anchor

t	Hose clamp -T20133-, see equivalent → Anchor

t	Push rod -T20134-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

t	Kit (case) -U-40200A-, see equivalent → Anchor

t  Kit (case) -U-40300-, see equivalent → Anchor

Outer ring of conical roller bearing: releasing   Note After expansion of the bearing outer ring, replacement of damaged disc is necessary, the disk thickness does not change, this could cause serious damage Always 1 mm in thickness.

Insert the outer ring of the conical roller bearing -A- into the gearbox casing Outer ring / bearing, 65 mm diameter: –  First fit the S1 shim, always 1 mm in thickness, underneath the outer ring. Outer ring / bearing, 68 mm diameter: –  Use the adapter -U-40200/10- with the adapter -U-40300/12-.   Note t  Always replace the conical roller bearings when the differential is removed. t  The roller bearings and their corresponding outer tracks are matched pairs.

Release the conical roller bearing inner rings   Note t  Always replace the conical roller bearings when the differential is removed. t  The inner rings of both conical roller bearings are extracted in the same manner form the differential housing.

Insert the conical roller bearing inner rings Outer ring / bearing, 38 mm diameter: –  Support the differential assembly on the vice. –  Place the adapter -U-40200/18- with the rebate side orientated towards conical roller bearing. –  Operate the vice until the bearing is inserted into its position. Outer ring / bearing, 41 mm diameter: –  Use the adapter -U-40200/10- with the adapter -U-40200/11-.

Release the outer ring of the conical roller bearing on the clutch housing side   Note Once the bearing ring is extracted, check if the washer is damaged; if necessary replace it.

Insert the outer ring of the conical roller bearing into the clutch housing Outer ring / bearing, 65 mm diameter: –  Use the clamp -T20133- connecting the shortest side to the seal. Outer ring / bearing, 68 mm diameter: –  Use the adapter -U-40200/10- with the adapter -U-40300/12-.

Fitting sun gear and planetary gears   Note t  To remove the planet gear carrier the securing sleeve must be drilled. t  Before drilling, the differential must be cleaned; cover the conical roller bearings to avoid penetration of shavings. –  Fit the complete assembly of thrust washers lubricated with gear oil. –  Fit the two sun gears and secure them (for example using the flanged axle). –  Fit the planetary gears off set by 180º and rock them -arrow-. –  Insert the planet gear shaft -arrow A- to the first planet gear. –  Fit the threaded parts -arrows B- on the sun gears, Fitting position: edge towards the sun gear. –  Insert the planet gear shaft to the final position and secure it with the pin.

Complete modified thrust washer assembly The entire thrust washer assembly has been designed with a projection -A- in the area of the holes. Correspondingly, a groove has been made in the differential housing -B-. –  Fit the complete assembly of thrust washers lubricated with gear oil. –  Fit the thrust washer assembly so that it is inserted into the groove -B- on the differential housing.