Skoda Workshop Service and Repair Manuals

Disassembling and assembling differential gear Special tools and workshop equipment required t  Counterholder -MP1-223 (3067)- 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 418A)- t  Press-on sleeve -MP3-412 (VW 455)- t  Drive bushing -MP3-427 (40-21)- t  Thrust piece -MP3-431 (3002)- t  Pressure spindle -MP3-448 (VW 408 A)- t  Distance sleeve -MP3-458/2 (VW 472/2)- t  Thrust plate -MP3-464 (30 - 205)- t  Pressure pipe -MP6-408 (30-14)- t  Pipe -MP6-419 (3259)- t  Pipe section -T30041 (2040)- t  Tapered-roller bearing extractor -V.A.G 1582- t  Gripper -V.A.G 1582/3- t  Interior extractor 46...58 mm, e.g. -Kukko 21/7- t  Countersupport, e.g. -Kukko 22/2-

t	Before installing heat the inner ring of the tapered-roller bearing 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 shaft

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	to remove cut tensioning sleeve Pos. 17 → Fig.

q	installing → Fig.

10 -	Small differential bevel gear

q	installing → Fig.

11 -	Stop disc compound

q	insert with gear oil

12 -	Flange shaft left

13 -	Sealing ring

q	for left flange shaft

q	replace with installed gearbox → Chapter

14 -	Outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

15 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

16 -	Differential gear housing

q	with gear pinion for final drive

17 -	Tensioning sleeve

q	to secure the differential bevel gear shaft

q	is cut when removing → Fig.

q	installing → Fig.

18 -	Inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

19 -	Outer ring/tapered-roller bearing

q	pressing out → Fig.

q	pressing on → Fig.

20 -	Adjusting washer

q	for the differential gear

q	Determine thickness → Chapter

21 -	Sealing ring

q	for right flange shaft

q	replace with installed gearbox → Chapter

22 -	Clutch housing

23 -	Gearbox housing

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 -3259 (MP6-419)- directly below the bearing support.

Remove inner rings/tapered-roller bearing –  Before fitting the extractor, position distance sleeve -VW 472/2 (MP3-458/2)- and thrust piece -3002 (MP3-431)- on the differential gear housing.   Note t  Both inner rings/tapered-roller bearings of the differential gear housing are removed in the same way. t  The inner and outer rings of the tapered-roller bearing are paired. Do not interchange!

Press on inner rings/tapered-roller bearing –  Press on inner ring/tapered-roller bearing with drive bushing -40-21 (MP3-427)- up to the stop. –  Support the opposite side of the inner ring with an insertion bushing -VW 455 (MP3-412)-. The shoulder of the insertion bushing -VW 455- points to the differential gear housing.   Note t  Both inner rings/tapered-roller bearings of the differential gear housing are pressed on in the same way. t  The inner and outer rings of the tapered-roller bearing are paired. Do not interchange!

Press the outer ring/tapered-roller bearing -A- out off the clutch housing B -  Interior extractor 46...58 mm, e.g. -Kukko 21/7- –  Position pipe -2040 (T30041)- directly on the feet of the interior extractor-B- and press out the outer ring/tapered-roller bearing -A-.

Press outer ring/tapered-roller bearing into the clutch housing

Press out differential bevel gear shaft The tensioning sleeve is cut during pressing out. –  Remove the remaining part of the tensioning sleeve from 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 the small differential bevel gears offset at 180° and slide in. –  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: Heel of the differential bevel gear. –  Drive in the differential bevel gear shaft up to end position and secure with new tensioning sleeve.