Volkswagen Workshop Service and Repair Manuals

Removing viscous coupling and rear axle housing from bevel gear housing

Servicing shaft bevel gear bearings => Page 39-127

Pressing bevel gear on and off input shaft => Page 39-134

Servicing bevel gear/input shaft bearings => Page 39-135

Servicing differential bearings => Page 39-140

Removing and installing rear axle housing to bevel box housing and building viscous coupling on => Page 39-142

Note:

When renewing

• ◆ Viscous coupling (item 3 )
• ◆ Bevel gear (item 26 )
• ◆ Differential complete with freewheel (item 37 )

or

• ◆ Shaft bevel gear (item 46 )

Observe rear final drive differences on vehicles with 4-cyl. engine or 6-cyl. engine.

1)     Adjustment work is required if these components are replaced => Adjustment overview Page 39-161 .

• Centralizing nut
• ◆ Removing and installing
  => Page 39-125
• O-ring
• ◆ Always renew

• Viscous coupling
• ◆ Functional check
  => Page 39-95
• ◆ Store only in installation position
• ◆ Identification
  => Page 39-97
• ◆ Allocate according to gearbox code letters using parts catalogue => Page 00-6
• Stud
• ◆ Before screwing into shaft bevel gear, coat with locking fluid
  D 000 600 A2
• Bevel gear housing1)
• ◆ Breather installation position
  => Fig.1
• Oil drain plug, 25 Nm
• ◆ With magnet

• Oil filler plug, 25 Nm
• ◆ Capacity and specification => Page 00-6
• ◆ Checking rear final drive oil => Page 39-111
• Hexagon bolt, 15 Nm
• Vacuum unit
• ◆ Controls freewheel lock electro-pneumatically
• ◆ Removing: unbolt and turn through 90°then take off
• ◆ Installing: => Page 39-145
• ◆ Installing breather hose => Page 39-105
• ◆ Functional check
  => Page 39-103
• ◆ Only use cold cleaning products to clean. Seal connections
• Sealing cap
• ◆ Renewing

• Circlip
• ◆ Use tool 30-23 to press into base of groove
• ◆ Always renew
• Dished washer
• ◆ Installation position: Cone points towards circlip
• Drive flange
• ◆ Pull in and out with VW 391
• Kombi bolt, 10 Nm
• Ring nut lock plate
• ◆ Installation position => Page 39-145
• Drive flange seal
• ◆ Drive in onto stop with sleeve 3158

• Ring nut1)
• ◆ Breather holes must not be blocked
• ◆ Breather holes position => Fig.2
• ◆ When reusing used bearings mark position before removing => Page 39-126 and when installing tighten again onto original position
• ◆ When installing new bearings observe adjustment instructions
  => Page 39-161
• Ring nut O-ring
• ◆ Always renew
• Hexagon bolt, 25 Nm
• Rear axle housing with dowel sleeves
• ◆ Qty. 2
• ◆ Ensure dowel sleeves are securely seated

• Hexagon bolt, 40 Nm
• ◆ Qty. 2
• ◆ To secure bearing support (item 22 ) in rear axle housing
• Bearing support1)
• ◆ Bolting off and on
  => Page 39-138
• Shim S2
• ◆ Note thickness
• ◆ Adjustment overview
  => Page 39-161
• Small taper roller bearing for mounting bevel gear1)
• Inner race:
• ◆ Pressing off => Page 39-136
• ◆ Pressing on => Page 39-137
• Outer race:
• ◆ Pressing out => Page 39-139
• ◆ Pressing in => Page 39-139

• Input shaft1)
• ◆ The input shaft serves as retainer and mounting for the bevel gear as well as the freewheel lock
• Bevel gear1)
• ◆ Is paired with shaft bevel gear
• ◆ Allocate according to gearbox code letters using parts catalogue => Page 00-6
• ◆ Pressing off => Page 39-134
• ◆ Pressing on => Page 39-134
• Large taper roller bearing for mounting bevel gear1)
• Inner race:
• ◆ Pulling off => Page 39-136
• ◆ Pressing on => Page 39-137
• Outer race:
• ◆ Pressing out => Page 39-135
• ◆ Pressing in => Page 39-135

• Switch lever mounting bolt, 55 Nm
• O-ring
• ◆ Always renew
• Switch mechanism for freewheel lock
• ◆ Installation position => Page 39-143
• Spring
• ◆ Internal diameter 41 mm
• ◆ Holds switch sleeve at correct distance to switch pins when switched off
• ◆ Installation position => Page 39-143
• Switch sleeve
• Balls (Qty. 6)
• ◆ Use a thick grease when inserting
• ◆ Installation position => Page 39-143
• Spring
• ◆ Internal diameter 60 mm
• ◆ Holds ball bearings in switched off condition
• ◆ Installation position => Page 39-143

• Sliding sleeve
• ◆ Installation position => Page 39-143
• Circlip
• ◆ Holds differential complete with freewheel via bore bearing (item 39 ) in position in rear axle housing (item 20 )
• ◆ Installation position => Page 39-140
• Differential complete with freewheel
• ◆ Pressing out => Page 39-141
• ◆ Pulling in => Page 39-141
• ◆ Dismantling and assembling differential
  => Page 39-147
• ◆ Functional check of freewheel (on vehicle) => Page 39-102
• ◆ Allocate according to gearbox code letters using parts catalogue => Page 00-6
• Circlip for ball bearing
• ◆ Lever out with large screwdriver

• Ball bearing for differential
• ◆ Drive out with VW 512
• ◆ Press in with VW 510
• ◆ Secure with circlip
• Oil seal
• ◆ For viscous coupling
• ◆ Drive in onto stop with 3158
• Hexagon nut for shaft bevel gear
• ◆ Removing => Page 39-127
• ◆ Installing => Page 39-132
• Small taper roller bearing for shaft bevel gear1)
• Inner race:
• ◆ Pressing off => Page 39-128
• ◆ Pressing on => Page 39-132
• Outer race:
• ◆ Pressing out => Page 39-128
• ◆ Pressing in => Page 39-131

• Spacer sleeve
• ◆ Always renew
• Shim S3
• ◆ Note thickness
• ◆ Adjustment overview
  => Page 39-161
• Large taper roller bearing for shaft bevel gear1)
• Inner race:
• ◆ Pulling off => Page 39-129
• ◆ Pressing on with tube VW 415 a
• Outer race:
• ◆ Knocking out => Page 39-129
• ◆ Pressing in => Page 39-130
• Shaft bevel gear1)
• ◆ Is paired with bevel gear
• ◆ Allocate according to gearbox code letters using parts catalogue => Page 00-6
• ◆ Pressing out => Page 39-128

→ Fig.1     Breather installation position

After pressing in the breather must project 16 mm (dimension "a") out of housing.

→ Fig.2     Position of breather holes (arrows A) in ring nut