Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling differential   Note t  Heat tapered roller bearing inner race to 100° C before pressing on. t  Heat adjusting ring for tapered roller bearing to 100 °C before pressing in tapered roller bearing outer race.

1 -	Differential cage with riveted gear for final drive

q	Final drive gear is riveted onto differential housing and then machined

q	If the differential or final drive gear is damaged, replace the differential housing together with the riveted final drive gear

q	Number of teeth on final drive gear → Chapter

2 -	Output shaft for drive flange

q	Removing and installing → Chapter

3 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Press on as → Fig.

4 -	Tapered roller bearing outer race

q	Remove and install only with adjusting ring heated

q	Drive out with a drift

q	Pressing in → Fig.

5 -	Bearing body for tapered roller bearing

q	Removing and installing differential → Chapter

6 -

O-ring

q	Always renew

7 -

O-ring

q	Always renew

8 -	Adjusting ring for tapered roller bearing

q	Removing and installing differential → Chapter

9 -	Output shaft for drive flange

q	Removing and installing differential → Chapter

10 -	Tapered roller bearing outer race

q	Remove and install only with adjusting ring heated

q	Drive out with a drift

q	Pressing in → Fig.

11 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

12 -	Drive bush

q	Drive off together with speedometer drive gear - → Item-

q	Drive on with drift

13 -	Speedometer drive wheel

q	Drive out with a drift

q	Fit on together with drive bush - → Item-

14 -	One-piece thrust washer

q	Place into differential housing before inserting bevel gears

15 -	Planet pinions

q	Installing → Fig.

16 -	Sun wheels

q	Installing → Fig.

17 -	Retaining ring

WARNING Do not remove retaining ring until after pulling off drive flange because compression spring is loaded.

18 -	Differential pinion pin

q	Drive out with a drift

q	When driving in, do not damage one-piece thrust washer

19 -	Spring pin

q	For securing differential pinion pin

q	Removing and installing spring pin with circumferential groove → Fig.

Pulling off tapered roller bearing inner race –  Place thrust piece -30-555- on differential cage.

Pressing on tapered roller bearing inner race

Inserting differential bevel gears –  Lubricate one-piece thrust washer with gear oil and install. –  Insert planet pinions, drive in shaft and secure with spring pin. –  Insert sun wheels offset 180° and swivel in, in direction of arrow.

Pressing in tapered roller bearing outer race –  With adjusting ring or bearing body heated, insert outer race and press in to stop.

Spring pin with circumferential groove t  Length of spring pin 28.5 mm Removing –  Pull out spring pin with side cutting pliers. Installing –  Drive in spring pin to stop.