SEAT Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Thrust piece -VW 442-

t	Removal and installing tool -VW 459/1-

t	Support -40-103-

t	Thrust plate -40-105-

t	Thrust piece -2007-

t	Tube -2040-

t	Thrust piece -2050-

t	Removal and installing tool -3111-

t	Tube -3146-

t	Tube -3259-

t	Assembly tool -3288-

t	Tube -3345-

t	Tapered roller bearing puller -V.A.G 1582-

t	Grip -V.A.G 1582/1-

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	-1-Internal puller -Kukko 21/8-

t	-4-Counterhold -Kukko 22/2-

t	-1-Two arm puller -Kukko 20/10- with hooks -Matra V/170-

t	Three arm puller -Kukko 45-2-

t	Heat tapered roller bearing inner race to 100° C before installing.

t	Always renew both tapered roller bearings together as a set.

t	If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential → Chapter.

1 -	Gearbox housing

2 -

Shim

q	For differential

q	Determining thickness → Chapter

3 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing into gearbox housing → Fig.

4 -	Tapered roller bearing outer race

q	Pulling off → Fig.

q	Pressing into differential cage → Fig.

5 -	Differential cage

q	With riveted final drive gear

6 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

7 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

8 -

Washer

q	Installation position: shoulder on inner circumference faces clutch housing.

9 -	Clutch housing

10 -	Spacer sleeve

q	Only for gearboxes with differential support and for which bearing housing for right flange shaft has been discontinued.

q	Allocation → Electronic parts catalogue (ETKA)

11 -	Differential support

q	Allocation → Electronic parts catalogue (ETKA)

12 -	Hexagon bolt, 40 Nm

q	Always renew

13 -	Hexagon bolt, 20 Nm

q	Always renew

q	Only on gearboxes with differential support

14 -

Seal

q	For right flange shaft

q	Renewing with gearbox installed → Chapter

15 -	Countersunk bolt, 25 Nm

q	Screw into threaded piece ( → Item)

16 -

O-ring

q	Always renew

q	Insert in groove in stub shaft ( → Item).

17 -	Dust plate

q	For stub shaft

q	Pressing off → Fig.

q	Pressing on → Fig.

18 -	Stub shaft

q	Removing and installing → Chapter

19 -	Compression spring

q	Installed behind stub shaft → Item or flange shaft → Item

20 -	Thrust washer

q	Installation position: shoulder faces spring, lugs face tapered ring

21 -	Tapered ring

q	With grooves to engage in thrust washer

q	Installation position: taper towards differential cage

22 -	Retaining ring

q	Holds tapered ring, thrust washer and spring in position when flange shaft or stub shaft is removed

23 -	Hexagon bolt, 20 Nm

q

Qty. 2

q	For bearing on gearbox carrier

24 -	Flange shaft

q	Modification: from gearbox date 05 06 1, a new flange shaft has been introduced

q	Removing and installing with gearbox installed → Chapter and → Chapter

q	Repairing flange shaft → Chapter

q	Allocation → Electronic parts catalogue (ETKA)

25 -	Bearing housing

q	With right flange shaft

q	Removing and installing with gearbox installed → Chapter and → Chapter

q	Dismantling and assembling → Chapter

q	Modification: discontinued from gearbox date 05 06 1

26 -

Sun wheel

q	Installing → Fig.

27 -	Differential pinion pin

q	Drive out using drift

q	Installing → Fig.

28 -	Spring pin

q	For securing differential pinion pin

q	Removing and installing → Fig.

29 -	Planet pinion

q	Installing → Fig.

30 -	Threaded piece

q	Installing → Fig.

31 -	One-piece thrust washer

q	Coat with gear oil when installing

32 -	Flange shaft

33 -	Nut, 40 Nm and turn 45° further

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly

q	Individual parts → Item, → Item, → Item and → Item have been discontinued

34 -	Final drive gear wheel

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly

q	Individual parts → Item, → Item, → Item and → Item have been discontinued

35 -	Differential cage

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly

q	Individual parts → Item, → Item, → Item and → Item have been discontinued

36 -

Bolt

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly

q	Individual parts → Item, → Item, → Item and → Item have been discontinued

Pulling tapered roller bearing outer race out of clutch housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller 56...70 mm, e.g. Kukko 21/8   Note! After pulling out, check washer for damage and renew if necessary.

Pressing tapered roller bearing outer race into clutch housing –  First insert washer. Installation position: shoulder on inner circumference faces clutch housing.

Pulling off tapered roller bearing inner races –  Before fitting extractor, position thrust plate -40-105- on differential cage.

Pressing on tapered roller bearing inner race

Pulling tapered roller bearing inner race from gearbox housing A -  Three arm puller, e.g. Kukko 45-2

Pressing tapered roller bearing inner race into gearbox housing –  Support gearbox housing with tube -3345- directly below bearing support.

Pulling off tapered roller bearing outer race A -  Two arm puller, e.g. Kukko 20/10, with hooks -Matra V/170-   Note! As soon as outer race has been raised slightly, loosen two arm puller and press hooks outwards.

Pressing tapered roller bearing outer race into differential cage and driving further to stop with copper mandrel

Removing and installing spring pin for differential pinion pin Removing –  Cover tapered roller bearing inner race to prevent possible damage and ingress of metal particles. –  Drive out spring pin with chisel, inserting chisel into circumferential groove. Installing –  Drive into differential cage to stop.

Installing differential bevel gears –  Lubricate one-piece thrust washer with gear oil and install. –  Install both sun wheels and secure (e.g. with flange shaft). –  Insert planet pinions offset 180° and pivot into position. –  Press in differential pinion pin (-arrow A-) to first planet pinion. –  Set threaded pieces (-arrows B-) in sun wheels. Installation position: shoulder to bevel gear –  Drive differential pinion pin into final position and secure with spring pin.

Pressing dust plate off stub shaft –  Apply tube -3146- to dust plate with large diameter inwards.

Pressing dust plate onto stub shaft