Volkswagen Golf Workshop Service and Auto Repair Manuals

• Bearing housing
• Shim S2
• Is always 1mm thick.
• Outer race
• ◆ Pulling out => Fig.10
• ◆ Knocking in =>Fig.11
• Bearing inner race
• ◆ Press off =>Fig. 1
• ◆ To fit, heat to 100° C and press fully home =>Fig. 2
• ◆ Adjust differential =>page 39-15
• ◆ Remove shaft for drive flange first. If replaced:

• Shaft for drive flange
• ◆ Turn slightly when pulling out as thrust washer tends to catch. Press in carefully when installing, do not damage thrust washers.
• Fit new
• ◆ 50 Nm
• ◆ Mod. =>Fig 5 and 6 .
• ◆ Differential bevel gear shaft secured with extended rivets =>page 39-19
• Crown wheel is matched to output shaft
• ◆ Press off =>Fig.3
• ◆ To fit, heat to 100° C =>Fig.4
• ◆ If gears are replaced, adjust output shaft =>page 35-20 .
• ◆ Mod. =>page 39-10
• Differential housing
• ◆ If replaced: Adjust differential, page 54 Mod. =>Fig.8

• Bearing inner race
• ◆ Pull off =>Fig.1
• ◆ To fit, heat to 100°C and press fully home =>Fig.2
• ◆ Remove shaft for drive flange first.
• ◆ If replaced, adjust differential =>page 39-15
• Outer race
• ◆ Pulling out =>Fig. 12
• ◆ Knocking in =>Fig. 13
• Shim S1
• ◆ Find thickness =>page 39-15
• Gearbox housing
• One-piece thrust washer
• From 13 12 6
• ◆ Lubricate with gear oil before installing. Install only in diff. housing with appropriate mark =>Fig.8

• Thrust washers
• Check for cracks and chipping.
• From 13 12 6 one-piece thrust washer
• Differential pinions
• ◆ Install =>Fig. 7
• Circlip
• ◆ Find thickness =>Fig. 9
• Pinion shaft
• ◆ Knock out with a drift, do not damage thrust washers when installing.

→ Fig.1     Pulling inner race off

•      A -     Puller such as Kukko 20/1 with 100 mm reach hooks.

→ Fig.2     Pressing inner race home

• ‒ Heat race to 100° first and install

→ Fig.3     Pressing crown wheel off

→ Fig.4     Heat crown wheel to about 100°C and install

•      A -     Centering pins (Local manufacture)

Modification

From Gearbox 07 08 5.

Crown wheel riveted to differential.

Repair instructions

• ‒ When renewing differential or crown wheel, drill rivets out with 12 mm drill from the centre punched or countersunk side and knock them out.

→ Fig.5     Drilling rivet heads

• ‒ After fitting new parts, secure crown wheel to housing with special bolts, lockplates and nuts - Part No. 171 498 088 (Repair kit).
• ‒ Use bolts from kit to guide crown wheel.

→ Fig.6     Tighten nuts to 70 Nm

→ Fig.7     Installing differential pinions

• ‒ Insert small pinions and thrust washers, drive shaft in and secure.
• ‒ Insert large pinions with thrust washers offset 180° and swing in.

Note:

In differential with thrust washer mark =>Fig.8 , lubricate washer with gear oil and install first.

Mod.:

From gearbox 13 12 6

Differential with one-piece thrust washer

→ Fig.8     Differential housing mark

In housing with this mark, install one-piece plastic thrust washer.

→ Fig.9     Find thickness of clirclip -arrow-

•      1 -     Differential housing
•      2 -     Differential pinion spindle
•      3 -     Differential pinion
•      4 -     Differential gear
•      5 -     Drive flange shaft
•      6 -     Circlip

• ‒ Press shaft against differential pinion spindle.
• ‒ Press differential gears against housing and press tick circlip into groove. If circlip jams at the sides, install thinner circlips.

Two circlips are available

→ Fig.10     Knocking out differential bearing outer race

→ Fig.11     Knocking in differential bearing outer race

→ Fig.12     Knocking out differential bearing outer race

→ Fig.13     Knocking in differential bearing outer race