Skoda Workshop Service and Repair Manuals

Disassembling and assembling the differential Special tools and workshop equipment required t  Pressure plate -MP3-406 (VW 401)- t  Pressure plate -MP3-407 (VW 402)- t  Thrust piece -MP3-423 (VW 407)- t  Thrust piece -MP3-448 (VW 408A)- t  Pressure washer -MP3-455 (VW 447H)- t  Pressure washer -MP3-456 (VW 447I)- t  Pressure plate -MP3-458 (VW 472)- t  Bushing -MP3-474 (3144)- t  Pressure plate -T30042 (2050)- t  Pipe -T30055 (3296)- t  Removal and pressing in device -T30064 (VW 459) - t  Ejector -3138- t  Interior extractor 46...58 mm, e.g. - Kukko 21/7- t  Two-arm extractor, e.g. -Kukko 44/2- t  Countersupport, e.g. -Kukko 22/2 -   Note t  Before installing, heat the inner rings/tapered-roller bearings and the crown wheel to 100°°C. t  Replace both tapered-roller bearings together. t  When replacing the tapered-roller bearing, the differential housing, the final drive cover, the drive shaft and the gearbox housing adjust the differential → Chapter.

1 -	Gearbox housing

q	is made out of aluminium or magnesium → Chapter

q	assign → Electronic Catalogue of Original Parts

2 -	Adjusting washer S2

q	Note thickness

q	Setting overview → Chapter

3 -	Right outer ring/tapered-roller bearing

q	removing → Fig.

q	installing → Fig.

4 -	Right inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

5 -	Crown wheel

q	paired with secondary shaft (drive train)

q	Assign the components by gearbox code letters → Chapter via the → electronic catalogue of original parts.

q	drive out with drift pin → Fig.

q	mounting on differential housing → Fig.

6 -	Differential housing

q	left bearing assembly modified as of 05.03

q	Assign the components by gearbox code letters → Chapter via the → electronic catalogue of original parts.

7 -	60 Nm and torque a further 45°

q	always replace → Electronic Catalogue of Original Parts

8 -	Left inner ring/tapered-roller bearing

q	remove → Fig.

q	pressing on → Fig.

As of 05.03 the differential housing of the bearing assembly for the left tapered-roller bearing was provided with a large radius at the inner stop. The left inner ring/tapered-roller bearing was adapted equivalently. Tapered-roller bearings of old fitting status must no longer be mounted in the new differential housings.

q	assign → Electronic Catalogue of Original Parts

9 -	Drive wheel for speedometer

q	removing and installing → Chapter

q	the drive gear must be carefully installed and without tilting onto the differential gear

q	do not excert any force otherwise the drive wheel can break

q	as of 06.03 is no longer fitted on vehicles with ABS

10 -	Left outer ring/tapered-roller bearing

q	left tapered-roller bearing modified as of 05.03

q	Assign the components by gearbox code letters → Chapter via the → electronic catalogue of original parts.

q	extracting → Fig.

q	installing → Fig.

11 -	Adjusting washer S1

q	Note thickness

q	Setting overview → Chapter

12 -

Cover

q	for final drive

13 -	Differential bevel gear large

q	installing → Fig.

14 -	Differential bevel gear shaft

q	drive out with drift

15 -	Tensioning sleeve

q	to secure the differential bevel gear shaft

q	removing and installing tensioning sleeve → Fig.

16 -	Differential bevel gear small

q	installing → Fig.

17 -	Stop disc compound

q	insert with gear oil

Remove rigth 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- –  After removal, inspect gauge shim for damage.

Press in right outer ring/tapered-roller bearing in the gearbox housing –  The pressure plate -MP3-458- is inserted with cone in the outer ring. –  Support the gearbox housing with -T30064- directly below the bearing support.

Remove right inner ring/tapered-roller bearing A -  Two-arm extractor, e.g. -Kukko 44/2- or -Kukko 20/10-   Note The differential gear housing has a recess below the bearing assembly for positioning the extractor -A-.

Press on right inner ring/tapered-roller bearing   Note The right and left inner rings/tapered-roller bearings are pressed on with the same pressure tools.

Remove left inner ring/tapered-roller bearing A -  Two-arm extractor, e.g. -Kukko 204/2-

Extract left outer ring/tapered-roller bearing from cover –  Unscrew the legs -A- and -B- sufficiently until they are positioned within the recess in the cover on the outer ring. –  After removal, inspect gauge shims for damage.

Press left outer ring/tapered-roller bearing into the cover

Remove crown wheel from housing

Heat crown wheel to 100 °C and mount. –  When mounting, guide crown wheel with locating pins -A- (self-tapping). –  Allow to cool for a while before tightening the fixing bolts. Then tighten the screws crosswise to tightening torque.   Caution Wear protective gloves.

removing and installing tensioning sleeve Removing –  Pull out tensioning sleeve with side cutter. Install –  drive in tensioning sleeve up to stop.

Install the differential bevel gears –  Install stop disc compound with gearbox oil. –  Insert large differential bevel gears. –  Insert the small differential bevel gears offset at 180°, then swivel into the end position -arrow-. –  Insert the differential bevel gear shaft up to end position and secure.