SEAT Workshop Service and Repair Manuals

Dismantling and assembling differential Consult the equivalence table for tools and equipment according to applicability among 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	Tappet -T20134-, see equivalent → Anchor

t	Extractor kit -T20140-

t	Kit (case) -U-40200A-

t  Kit (case) -U-40300-

t  Digital thermometer -SAT 4002-

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  Both tapered roller bearing inner races are pulled off the differential cage in the same way.

Insert the conical roller bearing inner rings   Note Before installing the bearing in the differential casing heat with electro-blower -SAT 1416- to 100 ºC. The temperature can be checked with digital thermometer -SAT 4002-. 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 thrust pad -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-.

Installing differential bevel gears   Note t  To remove the planet gear carrier the securing sleeve must be drilled. t  Clean differential before and after drilling, protecting tapered roller bearing from drillings. –  Lubricate one piece thrust washer with gear oil and install. –  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 planetary gear. –  Drive differential pinion pin into final position and secure with spring 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-. –  Lubricate one piece thrust washer with gear oil and install. –  Fit the thrust washer assembly so that it is inserted into the groove -B- on the differential housing.