Volkswagen Passat Workshop Service and Auto Repair Manuals

Special tools and workshop equipment required

• ◆ VW 402 Thrust plate
• ◆ VW 408 A Press tool
• ◆ VW 411 Press tool
• ◆ 30-205 Thrust plate
• ◆ 40-21 Press tool
• ◆ V.A.G 1582 Taper roller bearing puller

• ◆ VW 191
• ◆ VW 472/1 Thrust piece
• ◆ VW 472/2 Thrust piece
• ◆ VW 792 Thrust piece
• ◆ 3347 Assembly tool
• ◆ 2010

• ◆ VW 433 Thrust piece
• ◆ V.A.G 1582/6 Grip
• ◆ V.A.G 1582/6A Grip
• ◆ V.A.G 1582/11 Grip
• ◆ Kukko 21/7 Internal puller
• ◆ Kukko 22/2 Counter-support

• ◆ V.A.G 1582/3 Clamping ring

• ◆ 30-555 Thrust piece

• ◆ Heat taper roller bearing inner race to 100 °C before pressing on.
• ◆ Heat adjusting ring for taper roller bearing to 100 °C before pressing in taper roller bearing outer race.

• Differential housing with riveted gear for final drive
• ◆ Final drive gear is riveted onto differential housing and then machined
• ◆ If the differential or final drive gear is damaged, replace the differential housing together with the riveted final drive gear
• ◆ Number of teeth on final drive gear =>from Page 00-5
• ◆ The differential housings differ depending on the diameter of the taper roller bearings

• Output shaft/drive flange
• ◆ Removing and installing
  
• Taper roller bearing inner race
• ◆ There are different sizes of taper roller bearings. The fitting location can vary
• ◆ Pulling off => Fig.1 and Fig.3
• ◆ Pressing on => Fig.2 (with equal sized bearings on both sides)
• ◆ Pressing on => Fig.4
• Taper roller bearing outer race
• ◆ Remove and install only when adjusting ring heated
• ◆ Drive out with drift
• ◆ Pressing in => Fig.6
• Bearing body for taper roller bearing
• ◆ There are different types of bearing body
• ◆ Removing and installing => Removing and installing differential, Page 39-27
• ◆ Pulling off taper roller bearing/inner race => as Fig.9
• ◆ Pressing on => Fig.8
• ◆ Pressing on => Fig.10

• O-ring
• ◆ Always replace
• O-ring
• ◆ Always replace
• Adjusting ring for taper roller bearing
• ◆ Removing and installing => Removing and installing differential, Page 39-27
• Output shaft/drive flange
• ◆ Removing and installing => Removing and installing differential, Page 39-27
• Taper roller bearing outer race
• ◆ Remove and install only when adjusting ring heated
• ◆ Drive out with drift
• ◆ Pressing in => Fig.6

• Taper roller bearing inner race
• ◆ There are different sizes of taper roller bearings. The fitting location can vary
• ◆ Pulling off => as Fig.1 (with equal sized bearings on both sides)
• ◆ Pressing on => Fig.2
• ◆ Inserting => Fig.5
• Driver bush
• ◆ Drive off together with speedometer drive gear -item 13 -
• ◆ Drive on with drift
• Speedometer drive gear
• ◆ Drive out with a drift
• ◆ Fit on together with driver bush -item12 -
• One-piece thrust washer
• ◆ Place into differential cage before inserting bevel gears

• Small bevel gears
• Large bevel gears
• ◆ Inserting => Fig.5
• Circlip

• Shaft for bevel gears
• ◆ Drive out with a drift
• ◆ When driving in, do not damage one-piece thrust washer
• Spring pin
• ◆ For securing shaft for bevel gears
• ◆ Removing and installing => Fig. 11

→ Fig.1     Pulling off taper roller bearing inner race

• ‒ Use adapter V.A.G 1582/6A for larger bearings
• ‒ Place press piece 30-555 on differential housing.

→ Fig.2     Pressing on taper roller bearing inner race

→ Fig.3     Pulling out taper roller bearing outer race

→ Fig.4     Pressing in taper roller bearing outer race

→ Fig.5     Inserting differential bevel gears

• ‒ Insert one-piece thrust washer with gear oil.
• ‒ Insert small bevel gears, drive in shaft and secure with spring pin.
• ‒ Insert large bevel gears offset 180° and swivel in in direction of arrow.

→ Fig.6     Pressing in taper roller bearing outer race

• ‒ With adjusting ring or bearing body heated, insert outer race and press home as far as the stop.

→ Fig.7     Pulling out taper roller bearing outer race

A - Kukko 22/2 counter-support

B - Kukko 21/7 internal puller

→ Fig.8     Pressing in taper roller bearing outer race

→ Fig.9     Pulling off taper roller bearing inner race

• ‒ Place press piece VW 433 on bearing body.

→ Fig.10     Pressing on taper roller bearing inner race

→ Fig.11     Removing and installing planet wheel axis shaft spring pin

• ◆ Length of spring pin 28.5 mm

Removing

• ‒ Pull out spring pin with side cutting pliers.

Installing

• ‒ Drive in spring pin as far as the stop.