Volkswagen Workshop Service and Repair Manuals

Differential - dismantle and assemble

Special tools and workshop equipment required

t	Puller -VAG 1582-

t	Clamp -VAG 1582/3-

t	Pressure disc -VW 412-

t	Installation disc -40-105-

t	Plate -VW 401-

t	Plate -VW 402-

t	Pressure pin -VW 408A-

t	Placer -VW 473-

t	Pressure base -30-205-

t	Sleeve -3144-

t	Disc -2007-

t	40- 200 Nm Torquemeter -VAG 1332-

t  Inner puller -Kukko 21/6- t  Counter-support -KUKKO 22/2-   Note t  Heat taper roller bearing inner race to 212°F before installing t  Always renew both taper roller bearings together as a set t  Adjust differential if taper roller bearings, differential housing, gearbox housing or clutch housing are renewed → Chapter

1 -	Gearbox housing

2 -

Screw

3 -	Differential case

q	Bolt to final drive gear.

4 -	Final drive gear

q	Rivetted in production.

q	Is paired with output shaft, only renew as a set.

q	Remove → Fig.

q	Installation position → Fig.

q	Heat to 212°F, before installation.

q	Fit to differential housing → Fig.

q	Secure → Fig.

5 -	Backing plate

6 -	Nut; 70 Nm

7 -	Adjustment shim

q	For differential.

q	Check thickness → Chapter

8 -	Outer race/taper roller bearing

q	Remove → Fig.

q	Install → Fig.

9 -	Taper roller bearing inner race

q	Remove → Fig.

q	Install → Fig.

10 -	Differential housing

q	With rivetted final drive gear.

q	When renewing final drive gear drill out rivet heads → Fig.

q	Attach final drive gear with bolts → Fig.

11 -	Speedometer drive wheel

q	Fit onto differential housing as far as stop before pressing on inner race.

12 -	Taper roller bearing inner race

q	Remove → Fig.

q	Install → Fig.

13 -	Outer race/taper roller bearing

q	Remove → Fig.

q	Install → Fig.

14 -	Clutch housing

15 -

Bushing

q	To accept oil seal ( → Item)

q	Remove and install → Fig.

16 -

Seal

q	Renew with gearbox installed → Chapter.

17 -	Countersunk head bolt, 25 Nm

q	Bolt into threaded piece ( → Item).

18 -	Flange shaft

q	Remove and install → Chapter.

19 -	Spring for flanged shaft

q	Installed behind flanged shafts.

20 -	Thrust washer

q	Installation position: Shoulder towards spring, tongue to tapered ring.

21 -	Tapered ring

q	With grooves to secure thrust washer.

q	Installation position: Taper towards differential housing.

22 -

Circlip

q	Ensures that taper ring, thrust washer and spring are held in position when flange shaft is removed.

23 -	One-piece thrust washer

q	Install with gearbox oil.

24 -

Sun wheel

q	Install → Fig.

25 -	Threaded piece

q	Install → Fig.

26 -	Planet pinion axis shaft

q	Knock out with drift.

q	Install → Fig.

27 -	Spring pin

q	For securing planet pinion axis shaft.

q	Remove and install → Fig.

28 -	Planet pinion

q	Install → Fig.

29 -

Sun wheel

q	Install → Fig.

Press taper roller bearing outer race onto clutch housing –  First remove flange shaft seal mounting sleeve.

Press taper roller bearing outer race onto clutch housing No shim is installed in the clutch housing end.

Pull off taper roller bearing inner race –  Before fitting the extractor position Installation disc -40-105- on differential housing.   Note Both both taper roller bearing inner races are pulled off the differential housing in the same way

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

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

Press taper roller bearing outer race onto clutch housing –  Fit shim under outer race. –  Support gearbox housing with Sleeve -3144-, directly below bearing mounting.

Drill out rivet heads –  Drill out rivet heads with 12 mm drill from countersunk side and knockout with drift.   Note Clean differential before and after drilling, protect taper roller bearing from drillings

Press off final drive gear –  Position Installation disc - 40-105- on differential housing.

Installation position of final drive gear The circular groove -A- faces towards bolt on differential side.

Heat drive gear to drive shafts to approximately 212°F and install –  Use bolts -A- from repair kit to guide final drive gear into position during installation.

Bolting final drive gear and differential housing together Use special bolts with plates and nuts according to Electronic Parts Catalogue.

Remove and install planet wheel axis shaft spring pin