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  Pressure spindle -MP3-408 (VW 412)- t  Pressure spindle -MP3-448 (VW 408A)- t  Pipe section -MP3-450 (VW 415A)- t  Pipe section -MP3-451 (VW 422)- t  Thrust piece -MP3-459 (VW 473)- t  Pressure washer -MP3-467 (40-105)- t  Assembly device -MP5-402 (3301)- t  Pressure spindle -MP6-405 (VW 411)- t  Pipe -MP6-419 (3259)- t  Pipe -T30019 (3345)- t  Thrust plate -T30045 (3005)- t  Pipe -T30055 (3296)- t  Separating device 12...75 mm, e.g. - Kukko 17/1- t  Extractor, e.g. -Kukko 18/1- t  Interior extractor 46 up to 58 mm, e.g. -Kukko 21/7- t  Countersupport e.g. -Kukko 22/2- t  Extractor, e.g. -Kukko 204/2-

Remove outer ring/tapered-roller bearing from clutch housing A -  Countersupport, e.g. -Kukko 22/2- B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7-   Note t  Tighten the interior extractor -B- between the outer ring/tapered-roller bearing and the washer. t  After pulling out the washer check for damage, if necessary replace.

Press outer ring/tapered-roller bearing into the clutch housing –  First insert the washer.   Note Pay attention to the fitting position of the washer, the shoulder on the inside diameter points towards the gasket ring.

Removing inner ring/tapered-roller bearing A -  Extractor, e.g. -Kukko 204/2- B -  Thrust plate -MP3-467 (40-105)- –  Tighten the extractor-A- in the area of the flattened sides of the differential gear housing below the inner ring.   Note When pulling off the inner ring make sure the hooks do not bend outwards, if necessary tighten screw of locking element.

Press on inner ring/tapered-roller bearing

Removing inner ring/tapered-roller bearing A -  Extractor, e.g. -Kukko 18/1- B -  Separating device 12...75 mm, e.g. -Kukko 17/1-

Gearbox with right rigid shaft: Press on inner ring/tapered-roller bearing –  Place pressure plate -MP3-459- with small external diameter onto the inner ring/tapered-roller bearing. It must be possible to rotate the cage with the taper rollers freely when pressing on.

Gearbox with right flange shaft: Press on inner ring/tapered-roller bearing It must be possible to rotate the cage with the taper rollers freely when pressing on.

Four-wheel drive: Press on inner ring/tapered-roller bearing –  Place sleeve from the assembly device -MP5-402- with the opening -arrow- (large internal diameter) onto the inner ring/tapered-roller bearing.

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

Press in outer ring/tapered-roller bearing in the gearbox housing –  Support the gearbox housing with a pipe -T30019- directly below the bearing support.

Remove and install the tensioning sleeve for differential bevel gear shaft Removing –  Cover inner ring/tapered-roller bearing to avoid any possible damage and swarf. –  Drive out tensioning sleeve with a chisel, position the chisel in the circular slot. Install –  Drive into the differential gear housing up to the stop.

Four-wheel drive: Remove differential bevel gear shaft and tensioning sleeve for differential bevel gear shaft –  First drive in the tensioning sleeve -1- into the differential bevel gear shaft -2- flush. –  Then position the differential with the tensioning sleeve -arrow- pointing towards the pipe section -MP3-451- under the press. –  Then press out the differential bevel gear shaft.   Note If necessary remove the cut parts of the tensioning sleeve from the differential gear housing.

Four-wheel drive: Install tensioning sleeve –  Drive in the new tensioning sleeve -arrow- flush to the differential gear housing using a drift -1-.

Install differential bevel gears –  Install stop disc compound with gearbox oil. –  Insert both large differential bevel gears and secure (e.g. with flange shaft). –  Insert and swivel both small differential bevel gears into position with a 180° offset. –  Push in the differential bevel gear shaft -arrow A- up to the first small differential bevel gear. –  Insert the threaded parts -arrows B- in the large differential bevel gears. Fitting position: Shoulder towards the large differential bevel gears –  Drive in the differential bevel gear shaft up to end position and secure with tensioning sleeve.