Skoda Workshop Service and Repair Manuals

Disassembling and assembling the differential gear Special tools and workshop equipment required t  Rig tool -MP1-223 (3067)- t  Pressure plate -MP3-407 (VW 402)- t  Thrust piece -MP3-431 (3002)- t  Pipe section -MP3-450 (VW 415A)- t  Mandrel -MP3-511- t  Pipe section -MP3-4013 (VW421)- t  Two-arm extractor -Kukko 20/10- t  Extraction hook -Matra V/170- t  Interior extractor -Kukko 21/7- t  Countersupport -Kukko 22/2-   Note t  Before installing heat the inner ring of the tapered-roller bearing to 100°C. t  Replace both tapered-roller bearings together → Electronic Catalogue of Original Parts. t  When replacing the tapered-roller bearing of the differential housing, gearbox housing and clutch housing adjust the differential → Chapter.

1 -	Gearbox housing

2 -	Adjusting washer

q	for the differential gear

q	Determine thickness → Chapter

3 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

4 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

5 -	Differential gear housing with pinion

6 -	Drive wheel for speedometer

q	before pressing on the inner ring place it on the differential gear housing up to the stop

7 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

8 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

9 -	Clutch housing

10 -	Sealing ring

q	replace → Electronic Catalogue of Original Parts, → Chapter

11 -	Flange shaft

q	removing and installing → Chapter

12 -	Dust guard

q	for flange shaft

q	remove → Fig.

q	pressing on → Fig.

13 -

Circlip

q	always replace → Electronic Catalogue of Original Parts

14 -	Stop disc compound

q	insert with gear oil

15 -	Differential bevel gear large

q	installing → Fig.

16 -	Differential bevel gear small

q	installing → Fig.

17 -

Circlip

q	replace → Electronic Catalogue of Original Parts

18 -	Differential bevel gear shaft

q	Shaft has a different diameter, front side with centering hole means a smaller diameter

q	pressing out → Fig.

q	installing → Fig.

19 -	Pinion for final drive

q	is paired with the output shaft, when replacing, replace together → Electronic Catalogue of Original Parts

20 -	Differential gear housing

q	screw to pinion for final drive

21 -	Screw, 80 Nm

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

Press in outer ring/tapered-roller bearing in the gearbox housing –  Position adjusting washer under outside ring. –  Support the gearbox housing with a pipe section -MP3-450 (VW415A)- directly below the bearing support.

Remove inner rings/tapered-roller bearing –  Before fitting the extractor, position the pressure plate -MP3-431 (3002)- on the differential gear housing.   Note Both inner rings/tapered-roller bearings of the differential gear housing are removed in the same way.

Press on inner rings/tapered-roller bearing   Note The inner ring/tapered-roller bearing for the gearbox housing and clutch housing are pressed on with the same pressure tools.

Press outer ring/tapered-roller bearing out of clutch housing -A- Countersupport, e.g. countersupport -Kukko 22/2- -B- Interior extractor 46...58 mm, e.g. interior extractor -Kukko 21/7-

Press outer ring/tapered-roller bearing into the clutch housing   Note No adjusting washer is fitted at the side of the clutch housing. –  Support the clutch housing with a pipe section -MP3-450 (VW415A)- directly below the bearing hole.

Remove the dust guard of the flange shaft -A- Two-arm extractor, e.g. two-arm extractor -Kukko 20/10-, with extraction hooks -Matra V/170-

Press on the dust guard of the flange shaft

Press out the differential bevel gear shaft –  Remove the circlips of the differential gear shaft. –  Position the counterholder on the front side of the shaft with centering hole -arrow- and press on shaft.

Press on the differential bevel gear shaft –  Install stop disc compound with gearbox oil. –  Position the circlip on the side of the differential bevel gear shaft with a large diameter. –  Slide the differential bevel gear shaft with the smaller diameter (side with centering hole) into the differential gearbox housing. –  Slide the differential bevel gears onto the differential bevel gear shaft. –  Press the differential bevel gear shaft up to its end position and secure with a second circlip.

Installing the differential bevel wheels large –  Insert the large differential bevel gears with a 180° offset, then swivel into the end position -arrow-.