Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Gearbox support -VW 353-

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408A-

t	Press tool -VW 412-

t	Thrust plate -40-105-

t	Thrust plate -3005-

t	Tube -3259-

t	Tube -3296-

t	Wheel bearing tube -3345-

t	Torque wrench -V.A.G 1332-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/6-

t	Internal puller -1 Kukko 21/7-

t	Puller -2 - Kukko 18/1-

t	Splitter -3 - Kukko 17/1-

t	Counter support -4 - Kukko 22/2 -

Note t  Heat tapered roller bearing inner race to 100° C before installing. t  Always renew both tapered roller bearings together as a set. t  If tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed, adjust differential → Chapter.

1 -	Gearbox housing

2 -

Bolt

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly.

q	Individual parts → Item, → Item, → Item , → Item and → Item have been discontinued.

3 -	Differential cage

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly.

q	Individual parts → Item, → Item, → Item , → Item and → Item have been discontinued.

4 -	Final drive gear wheel

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly.

q	Individual parts → Item, → Item, → Item , → Item and → Item have been discontinued.

5 -	Backing plate

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly.

q	Individual parts → Item, → Item, → Item , → Item and → Item have been discontinued.

6 -	Nut, 40 Nm and turn 45° further

q	Always renew

q	The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly.

q	Individual parts → Item, → Item, → Item , → Item and → Item have been discontinued.

7 -	Clutch housing

8 -

Shim

q	For differential

q	Determining thickness → Chapter

9 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

10 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

11 -	Differential cage

12 -	Tapered roller bearing inner race

q	Before removing, pull connecting piece off ( → Item).

q	Pulling off → Fig.

q	Pressing on → Fig.

13 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

14 -

Washer

q	Allocation → Electronic parts catalogue (ETKA)

15 -	Bevel box connecting piece

q	Pressed onto differential housing

q	Press on and off only with differential housing removed

q	Pulling off → Fig.

q	Pressing on → Fig.

16 -

Seal

q	For right flange shaft

q	Left and right diameters differ

q	Renewing with gearbox installed → Chapter

17 -

Bevel box

q	Removing and installing with gearbox installed → Chapter

q	Removing and installing with gearbox removed → Anchor

18 -	Hexagon bolt, 40 Nm and turn 45° further

q	Always renew

19 -

Washer

20 -	Countersunk bolt, 25 Nm

q	Screw into threaded piece ( → Item)

21 -	Right flange shaft

22 -

O-ring

q	Always renew

23 -

O-ring

q	Always renew

24 -

O-ring

q	Always renew

25 -

Sun wheel

q	Installing → Fig.

q	Allocation → Electronic parts catalogue (ETKA)

26 -	Differential pinion pin

q	Drive out using drift

q	Installing → Fig.

q	Allocation → Electronic parts catalogue (ETKA)

27 -	Spring pin

q	For securing differential pinion pin

q	Allocation → Electronic parts catalogue (ETKA)

q	Removing and installing → Fig.

28 -	Planet pinion

q	Installing → Fig.

q	Allocation → Electronic parts catalogue (ETKA)

29 -	Threaded piece

q	Installing → Fig.

q	Allocation → Electronic parts catalogue (ETKA)

30 -	One-piece thrust washer

q	Coat with gear oil when installing

q	Allocation → Electronic parts catalogue (ETKA)

31 -	Retaining ring

q	Holds tapered ring, thrust washer and spring in position when flange shaft is removed

32 -	Tapered ring

q	With grooves to engage in thrust washer

q	Installation position: taper towards differential cage

33 -	Thrust washer

q	Installation position: shoulder faces spring, lugs face tapered ring

34 -	Compression spring for flange shaft

q	Installed behind flange shafts

35 -	Left flange shaft

q	From gearbox date 19 05 3, with protective ring

q	Protective ring protects seal from dirt.

q	Lever off protective ring using screwdriver on alternate sides.

q	Install with indentation facing away from threaded hole in flange shaft

q	Push on protective ring to stop by hand

q	Protective ring must engage in flange shaft

36 -

Seal

q	For left flange shaft

q	Left and right diameters differ

q	Renewing with gearbox installed → Chapter

Pulling tapered roller bearing outer race out of clutch housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7-   Note After pulling out, check washer for damage and renew if necessary.

Pressing tapered roller bearing outer race into clutch housing –  First insert washer.

Pulling off tapered roller bearing inner races –  Before fitting extractor, position thrust plate -40-105- on differential cage.   Note Both tapered roller bearing inner races are pulled off the differential cage in the same way.

Pressing on tapered roller bearing inner race   Note The tapered roller bearing inner races for gearbox housing and clutch housing are pressed on with the same press tools.

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Support gearbox housing with wheel bearing tube -3345- directly below bearing support.

Removing and installing spring pin for differential pinion pin Removing –  Cover tapered roller bearing inner race to prevent possible damage and ingress of metal particles. –  Drive out spring pin with chisel, inserting chisel into circumferential groove. Installing –  Drive into differential cage to stop.

Installing differential bevel gears –  Lubricate one-piece thrust washer with gear oil and install. –  Install both sun wheels and secure (e.g. with flange shaft). –  Insert planet pinions offset 180° and pivot into position. –  Press in differential pinion pin -arrow A- to first planet pinion. –  Set threaded pieces (-arrows B-) in sun wheels. Installation position: shoulder to bevel gear –  Drive differential pinion pin into final position and secure with spring pin.

Pulling off connecting piece -A- B -  Puller, e.g. -Kukko 18/1- C -  Splitter, 12 … 75 mm, e.g. -Kukko 17/1-

Pressing on connecting piece -A- for bevel box