Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ V.A.G 1582 Puller
• ◆ V.A.G 1582/3 Grip
• ◆ VW 412 Press tool
• ◆ 40-105 Thrust plate
• ◆ VW 401 Thrust plate
• ◆ VW 402 Thrust plate

Special tools and workshop equipment required

• ◆ VW 408 A Press tool
• ◆ VW 473 Thrust piece
• ◆ 30-205 Thrust plate
• ◆ 3144 Sleeve
• ◆ 2007 Thrust pad
• ◆ V.A.G 1332 Torque wrench

Special tools and workshop equipment required

• ◆ 1 - Kukko 21/7 Internal puller
• ◆ 4 - Kukko 22/2 Counter support

Notes:

• ◆ Heat taper roller bearing inner race to
  100 °C before installing.
• ◆ Always renew both taper roller bearings together as a set.
• ◆ If differential housing, gearbox housing or clutch housing taper roller bearings are renewed adjust differential .

• Gearbox housing
• Bolt
• Differential cage
• ◆ Bolt to final drive gear

• Final drive gear wheel
• ◆ Rivetted in production
• ◆ Is paired with output shaft, only renew as a set
• ◆ Pressing off => Fig.8
• ◆ Installation position => Fig.9
• ◆ Heat to 100 °C before installing
• ◆ Fit to differential housing
  => Fig.10
• ◆ Bolted => Fig.11
• Backing plate
• Nut, 70 Nm
• Shim
• ◆ For differential
• ◆ Determining thickness => page 39-23
• Taper roller bearing outer race
• ◆ Driving out => Fig.5
• ◆ Pressing in => Fig.6

• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig.4
• Differential housing
• ◆ With rivetted final drive gear
• ◆ When renewing final drive gear drill out rivet heads => Fig.7
• ◆ Attaching final drive gear with bolts
  => Fig.11
• Speedometer drive wheel
• ◆ Fit onto differential housing as far as stop before pressing on inner race
• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig.4

• Taper roller bearing outer race
• ◆ Knocking out => Fig.1
• ◆ Pressing in => Fig.2
• Clutch housing
• Sleeve
• ◆ Installed in conjunction with springs behind flange shafts
• ◆ To accept oil seal (item 16 )
• ◆ Removing and installing
  => Page 34-91
• Oil seal
• ◆ Renewing => Page 39-1
• Counter-sunk head bolt, 25 Nm
• ◆ Bolt into threaded piece (item25 )

• Flange shaft
• ◆ Removing and installing
  => Page 39-1
• Spring for flanged shaft
• ◆ Installed behind flanged shafts
• Thrust washer
• ◆ Installation position:
  Shoulder towards spring, tongue to tapered ring
• Tapered ring
• ◆ With grooves to secure thrust washer
• ◆ Installation position: Taper towards differential housing
• Securing clip
• ◆ Ensures taper ring, thrust washer and spring are held in position when flange shaft is removed

• One-piece thrust washer
• ◆ Coat with gearbox oil when installing
• Sun wheel
• ◆ Installing => Fig. 13
• Threaded piece
• ◆ Installing => Fig. 13
• Planet pinion axis shaft
• ◆ Knock out with drift
• ◆ Installing => Fig. 13
• Spring pin
• ◆ For securing planet pinion axis shaft
• ◆ Removing and installing => Fig.12
• Planet pinion
• ◆ Installing => Fig. 13
• Sun wheel
• ◆ Installing => Fig. 13

→ Fig.1     Knocking taper roller bearing outer race out of clutch housing

• ‒ First remove flange shaft seal mounting sleeve on gearboxes with springs behind flange shaft.

→ Fig.2     Pressing taper roller bearing outer race into clutch housing

No shim is installed in the clutch housing end.

→ Fig.3     Pulling off taper roller bearing inner race

• ‒ Before fitting the extractor position press piece 40-105 on differential housing.

Note:

Both both taper roller bearing inner races are pulled off the differential housing in the same way.

→ Fig.4     Pressing on taper roller bearing inner race

Note:

The taper roller bearing inner races for gearbox housing and clutch housing are pressed on with the same press tools.

→ Fig.5     Pulling taper roller bearing outer race out of gearbox housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

→ Fig.6     Pressing taper roller bearing outer race into gearbox housing

• ‒ Fit shim under outer race.
• ‒ Support gearbox housing with sleeve 3144 directly below bearing mounting.

→ Fig.7     Drilling out rivet heads

• ‒ Drill out rivet heads with 12 mm drill from countersunk side
  and knock-out with drift.

Note:

Clean differential before and after drilling, protect taper roller bearing from drillings.

→ Fig.8     Pressing off final drive gear

• ‒ Place thrust piece 40-105 on differential housing.

→ Fig.9 Installation position of final drive gear wheel

The circular groove -A- faces towards bolt-on side of differential.

→ Fig.10     Heating final drive gear wheel to approx. 100 °C and installing

• ‒ Use bolts -A- from repair kit to guide final drive gear into position during installation.

→ Fig.11      Bolting final drive gear and differential housing together

Use special bolts with plates and nuts according to parts catalogue.

→ Fig.12     Removing and installing planet wheel axis shaft spring pin

Removing

• ‒ Cover taper roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.
• ‒ Knock-out spring pin with chisel, inserting chisel into circumferential groove.

Installing

• ‒ Knock fully into the differential cage.

→ Fig.13      Installing sun wheels and planet pinions

• ‒ Lubricate one piece thrust washer with gearbox oil and install.
• ‒ Install both sun wheels and secure (e.g. with flanged shaft).
• ‒ Insert planet wheels (180°apart) and pivot into position.
• ‒ Push planet wheel axis shaft (arrow -A-) in until first planet wheel.
• ‒ Position threaded pieces (arrow -B-) in sun wheels
  Installation position: step towards sun wheel
• ‒ Drive planet wheel axis shaft into final position and secure with spring pin.