Skoda Workshop Service and Repair Manuals

Disassembling and assembling differential gear Special tools and workshop equipment required t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Pressure spindle -MP3-408 (VW 412)- t  Pipe section -MP3-409 (VW 418 A)- t  Thrust piece -MP3-411 (VW 454)- t  Press-on sleeve -MP3-412 (VW 455)- t  Distance sleeve -MP 3-458/2- t  Pressure washer -MP3-413 (VW 510)- t  Pressure pipe -MP6-408 (30-14)- t  Thrust piece -MP3-431 (3002)- t  Counterholder -MP1-223 (3067)- t  Pipe -MP6-419 (3259)- t  Pipe for the wheel bearing -T30019 (3345)- t  Tapered-roller bearing extractor -V.A.G 1582- t  Release tool -V.A.G 1582/4- t  Interior extractor -Kukko 21/7- t  Countersupport -Kukko 22/2- t  Drive bushing -MP3-427 (40-21)- t  Gripper -V.A.G 1582/3- t  Hot-air blower -V.A.G 1416-

t	Before installing, heat the inner ring/tapered-roller bearing with the hot-air blower -V.A.G 1416- to 100°C.

t	Replace both tapered-roller bearings together.

t	When replacing the tapered-roller bearings, the differential housing, the gearbox housing or the clutch housing, set the differential gear → Chapter.

1 -	Conical screw, 25 Nm

q	screw into threaded piece Pos. 8

2 -	Right flange shaft

3 -	Pressure spring for flange shaft

q	fitted behind flange shafts

4 -	Thrust washer

q	Fitting position: Collar towards pressure spring

5 -	Conical ring

q	Fitting position: Cone towards differential gear housing

6 -

Circlip

q	holds the conical ring, stop disc and pressure spring in position when the flange shaft is removed

7 -	Large differential bevel gear

q	installing → Fig.

8 -	Threaded part

q	installing → Fig.

9 -	Differential bevel gear shaft

q	when removing, the tensioning sleeve Pos. 18 is cut out → Fig.

q	installing → Fig.

10 -	Small differential bevel gear

q	installing → Fig.

11 -	Stop disc compound

q	when installing moisten with gearbox oil

12 -	Flange shaft left

13 -	Seal ring for left flange shaft

q	replace with installed gearbox → Chapter

14 -	Adjusting washer S1

q	for differential gear

q	always 1 mm thick

q	on gearboxes as of production date 12.06 the adjusting washer S1 for outer ring/tapered-roller bearing is not fitted → Chapter

q	Bearing pedestal for outer ring/tapered-roller bearing is adapted

15 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

16 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

17 -	Differential gear housing

q	with gear pinion for final drive

18 -	Tensioning sleeve

q	to secure the differential bevel gear shaft

q	is cut when removing → Fig.

19 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

20 -	Outer ring/tapered-roller bearing

q	pressing out → Fig.

q	installing → Fig.

21 -	Adjusting washer S2

q	for differential gear

q	Determine thickness → Chapter

22 -	Seal ring for right flange shaft

q	replace with installed gearbox → Chapter

23 -	Gearbox housing

q	repairing → Chapter

q	on gearboxes as of production date 12.06 the adjusting washer S1 for outer ring/tapered-roller bearing is not fitted → Chapter

q	Bearing pedestal for outer ring/tapered-roller bearing is adapted

24 -	Clutch housing

q	repairing → Chapter

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 –  Position adjusting washer S1 always 1 mm thick, under the outer ring. –  Support the gearbox housing with a pipe -MP6-419 (3259)- directly below the bearing support.

Remove inner rings/tapered-roller bearing   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   WARNING Wear protective gloves! –  Before pressing on, heat the inner ring/tapered-roller bearing with the hot-air blower -V.A.G 1416- to approx. 100°C. –  Support the opposite side of the inner ring with an insertion bushing -MP3-412 (VW 455)-.

Press the outer ring/tapered-roller bearing -A- out off the clutch housing B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7- –  While doing so tighten the interior extractor behind the outer ring/tapered-roller bearing.

Press outer ring/tapered-roller bearing into the clutch housing –  Support the clutch housing with a pipe -T30019 (3345)- directly below the bearing support.

Removing inner ring/tapered-roller bearing –  Before fitting the extractor, position distance sleeve -MP 3-458/2- and thrust piece -MP3-431 (3002)- on the differential gear housing.

Press on inner ring/tapered-roller bearing   WARNING Wear protective gloves! –  Before pressing on heat the inner rings/tapered-roller bearing to approx. 100°C.

Press out differential bevel gear shaft The tensioning sleeve is cut during pressing out. –  Drive the remaining part of the tensioning sleeve out of the differential gear housing.

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 both small differential bevel gears 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. –  Drive in the differential bevel gear shaft up to end position and secure with tensioning sleeve.