Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ → Drill off rivet heads, if equipped, with 12 mm drill from depression side and drive out with drift.

Note:

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

• ‒ → Heat differential with gear wheel to 120 °C on a hot plate, thereby continually check the temperature of the gear wheel with Mini-tester V.A.G 1362. Place on ring 2006A so that the heat is directed directly into the gear wheel.

• ‒ → Place ring 2006A on press table with chamfer on inner diameter towards table. Then place heated toothed wheel with differential on ring.
• ‒ Fit press piece 2007 and press toothed wheel off differential.

Installing

When renewing the final drive gear ensure correct ratio (number of teeth) .

Installation position:

• ‒ → The circumferential groove (arrow) faces towards differential bevel gear mounting.

Gearboxes with bonded final drive gear wheel

• ‒ Before assembling gear wheel and differential housing thoroughly clean seating face with a wire brush and scraper (do not use abrasive paper). The seating face must also be oil and grease-free.
• ‒ → Coat the cleaned seating face on differential housing evenly with locking fluid AMV 185 100 01.

• ‒ Heat gear wheel for final drive on a hot plate to approx.150 °C, thereby continually check the gear wheel temperature with Minitester V.A.G 1362.
• ‒ → Place ring 2006A on press table with the chamfer on inner diameter facing upwards. Place final drive gear wheel heated to 150 °C centrally on ring, with larger chamfer on gear wheel (arrow) uppermost and depression downwards. Insert differential, pretreat with locking fluid AMV 185 100 01.

Notes:

• ◆ To ensure that the gear wheel is seated perfectly fit differential quickly on to stop without a pulse.
• ◆ If when inserting differential in the gear wheel the parts cant or stick then the assembling procedure is to be stopped immediately. Press gear wheel off and start assembling sequence from the beginning again.

• ‒ → Maintain the press pressure for one to two minutes after the components are assembled until a complete heat exchange is completed.

Gearboxes with bolted final drive gear wheel

• ‒ Assemble differential and gear wheel with special bolts.

Tightening torque

Final drive gear to differential 70 Nm