Skoda Workshop Service and Repair Manuals

Disassembling and assembling differential gear Special tools and workshop equipment required t  Pressure plate -MP3-407 (VW 402)- t  Drive bushing -MP3-427 (40 - 21)- t  Thrust piece -MP3-448 (VW 408 A)- t  Pressure washer -MP3-456 (VW 447 i)- t  Thrust plate -MP3-464 (30 - 205)- t  Thrust plate -MP3-467 (40 - 105)- t  Pressure plate -MP3-484 (30 - 555)- t  Thrust piece -MP6-405 (VW 411)- t  Assembly device -T30069 (VW 792)- t  Tapered-roller bearing extractor -V.A.G 1582- t  Gripper -V.A.G 1582/3- t  Gripper -V.A.G 1582/6A- t  Gripper -V.A.G 1582/11- t  Interior extractor 46...58 mm e.g. -Kukko 21/7- t  Countersupport e.g. -Kukko 22/2- t  Two-arm extractor -T10040-

t	Before pressing on the inner ring/tapered-roller bearing heat up to 100°C.

t	Adjusting ring for tapered roller bearing - before pressing in outer ring/tapered roller bearing - heat up to 100°C.

1 -	Differential gear housing

q	with riveted pinion for final drive

q	The pinion for the final drive is riveted on the differential gear housing and subsequently machined

q	if the differential gear housing or the pinion for the final drive is damaged, the differential gear housing is replaced together with the riveted pinion for the final drive

q	Number of teeth of the final drive pinion → Chapter

q	there are various differential gear housings depending on the diameters of the tapered-roller bearings.

2 -	Output shaft for joint flange

q	removing and installing → Chapter

3 -	Inner ring/tapered-roller bearing

q	there are different sizes of tapered-roller bearings. The fitting position can vary

q	remove the two “identical” bearings on both sides → Fig.

q	remove the “larger” bearing → Fig.

q	press on → Fig. (for bearings of equal size on both sides)

q	press into the housing for the “larger” bearing on one side → Fig.

4 -	Outer ring/tapered-roller bearing

q	only remove and install if the bearing body is heated Pos. 5

q	drive out with drift

q	installing → Fig.

5 -	Bearing body for tapered-roller bearing

q	there are various bearing bodies

q	removing and installing → Chapter

q	Remove inner rings for tapered-roller bearing → Fig.

q	Press in outer ring for tapered-roller bearing → Fig.

q	Press on inner ring for tapered-roller bearing → Fig.

6 -

O-ring

q	always replace → Electronic Catalogue of Original Parts

7 -

O-ring

q	always replace → Electronic Catalogue of Original Parts

8 -	Adjusting ring for tapered roller bearing

q	removing and installing → Chapter

9 -	Output shaft for joint flange

q	removing and installing → Chapter

10 -	Outer ring/tapered-roller bearing

q	only remove and install if the adjusting ring is heated Pos. 8

q	pull out → Fig., if necessary drive out with drift

q	installing → Fig.

11 -	Inner ring/tapered-roller bearing

q	there are different sizes of bearings

q	before detaching, remove Pos. 12 and 13

q	detach → Fig. (for bearings of equal size on both sides)

q	pressing on → Fig.

12 -	Tappet bushing

q	remove together with drive wheel for speedometer Pos. 13

q	remove with a drift

13 -	Drive wheel for speedometer

q	drive out with drift

q	position with tappet bushing Pos. 12

14 -	Stop disc compound

q	position in the differential gear housing before inserting the differential bevel gears

15 -	Differential bevel gear, small

q	inserting → Fig.

16 -	Differential bevel gear, large

q	inserting → Fig.

17 -

Circlip

q	remove circlip only after removing the joint flange, as the pressure spring is pretensioned

q	removing → Fig.

18 -	Differential bevel gear shaft

q	for removing, remove tensioning sleeve Pos. 19

q	drive out with drift

q	when driving in, do not damage stop disc compound

19 -	Tensioning sleeve

q

replace

q	to secure the differential bevel gear shaft

q	removing and installing → Fig.

Detach the inner ring of the “smaller” tapered-roller bearing –  Fit pressure plate -MP3-484 (30 - 555)- or thrust plate -MP3-467 (40 - 105)- onto differential gear housing. –  Use gripper -V.A.G 1582/6A- for larger bearing.

Press on inner ring/tapered-roller bearing On certain bearings, the pipe section -MP3-429 (2010)- can also be used instead of the drive bushing -MP3-427 (40 - 21)-.   Note If this is the case, the bearings must be of equal size on both sides. Therefore, the installation is the same on the other side.

Pull off the outer ring of the “larger” bearing

Press in the outer ring of the “larger” bearing

Insert differential bevel gears –  Insert stop disc compound with axle oil. –  Insert small differential bevel gears, drive in differential bevel gear shaft and secure with tensioning sleeve. –  Insert large differential bevel gears with a 180° offset and swivel in -direction of arrow-.

Pressing on outer ring/tapered-roller bearing –  Insert outer ring when adjusting ring or bearing body is heated and press on up to the stop.

Remove outer ring of tapered-roller bearing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-

Press in outer ring of tapered-roller bearing

Remove inner ring of tapered-roller bearing –  Position the thrust washer -MP3-456 (VW 447 i)- on the bearing body.

Press on inner ring of tapered-roller bearing –  Before pressing, heat inner ring to approx. 100°C.

Remove and install the tensioning sleeve for differential bevel gear shaft t  Length of tensioning sleeve 28.5 mm Removing –  Pull out tensioning sleeve with side cutter. Install –  Replace tensioning sleeve. –  Drive in tensioning sleeve up to stop.