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 408A-

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	Thrust piece -2050-

t	Tube -3259-

t	No longer required removing and installing tool -3111-

t  Assembly tool -3288- t  Tube -3345- t  Torque wrench -V.A.G 1331- t  Tapered roller bearing puller -V.A.G 1582- t  Grip -V.A.G 1582/1- t  Three arm puller - Kukko 45-2 -

t  Internal puller -1 Kukko 21/8-

t  Counter support -4 - Kukko 22/2 - t  Two arm puller -1 -Kukko 20/10- with hooks -Matra V/170-   Note! 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	Allocation → Electronic parts catalogue (ETKA)

9 -	Clutch housing

10 -

Seal

q	For right flange shaft

q	Renewing with gearbox installed → Chapter

11 -

Bevel box

q	Removing and installing with gearbox installed → Chapter

q	Removing and installing with gearbox removed → Chapter

q	Dismantling and assembling → Chapter

12 -

O-ring

q	Always renew

13 -

O-ring

q	Always renew

14 -

O-ring

q	Always renew

15 -	Bolt, 40 Nm

q	Always renew

16 -	Countersunk bolt, 25 Nm

q	Screw into threaded piece → Item

17 -	Right flange shaft

18 -	Compression spring

q	Installed behind right flange shaft → Item

19 -	Thrust washer

q	Installing → Chapter

20 -

Sun wheel

q	Installing → Fig.

21 -	Differential pinion pin

q	Drive out using drift

q	Installing → Fig.

22 -	Spring pin

q	For securing differential pinion pin

q	Removing and installing → Fig.

23 -	Planet pinion

q	Installing → Fig.

24 -	Threaded piece

q	Installing → Fig.

25 -	One-piece thrust washer

q	Coat with gear oil when installing

26 -	Retaining ring

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

27 -	Tapered ring

q	With grooves to engage in thrust washer

q	Installation position: taper towards differential cage

28 -	Thrust washer

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

29 -	Compression spring

q	Installed behind left flange shaft → Item

30 -	Left flange shaft

31 -

Seal

q	For left flange shaft

q	Renewing with gearbox installed → Chapter

32 -	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

33 -	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

34 -	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

35 -

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.

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.