Differential, Removing and Installing

Special tools and equipment
^ VW771 slide hammer - complete set
^ Plug insert SW27 3257
^ Kukko 21/3 extractor

Notes:
^ Removal and installation is also possible with transmission installed.
^ The differential can be installed and removed without removing shift mechanism, drive flange and drive pinion. Removal of the components mentioned above is necessary if the differential must be adjusted.
^ Drive axles with polygon bearings are installed in all transmissions.
^ Polygon bearings can only be replaced together with drive flange.
^ Look for visible damage of polygon bearings.
^ Rough running of the polygon bearings with the drive flange removed is no sign for faulty bearings. An acoustic test can only be performed in installed condition.
^ A spacer ring is installed between the polygon bearing and differential pinion for drive flanges with a spline diameter of 30 mm.
^ Adjustments are required when replacing components marked with 1). List of adjustments.





1. Transmission - housing
2. Oil seal
^ Replace
3. Circlip
^ Replace
^ Removing and installing see Fig. 1
4. Spacer ring
^ Is only fitted with drive axles that have a spline diameter of 30 mm
^ Removing see Fig. 2
^ Installing see Fig. 3
5. Drive flange
^ Removing and installing
^ Drive flange assembly see Fig. 4
6. Differential
^ Can also be removed without removing transmission
^ Disassembling and assembling
7. Cover
^ Seal with AMV 1 88 000 02
8. Torx bolt, 25 Nm
9. Speedometer drive wheel
^ Removing and installing
^ Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use force; the drive wheel can break easily





Fig. 1 Removing and installing circlip
- Clamp drive flange in vice, using soft jaws. Use new circlip -A- to press old circlip out of groove in drive flange.





Fig. 2 Removing spacer ring
B - Internal puller 18.5-23.5 mm, e.g. Kukko 21/3
- If the spacer ring is tight pull out using the multi-purpose tool VW 771.





Fig. 3 Installing spacer ring
- Drive new spacer ring in onto stop, when doing this do not cant ring.





Fig. 4 Drive flange assembly
1. Drive flange
2. Needle bearing (polygon bearing)
3. Spacer ring
4. Spacer ring - additionally fitted on shafts with 30 mm spline diameter
5. Circlip

Note: The needle bearing (polygon bearing) does not turn easily when the drive axle is removed. This does not indicate that the bearing is faulty.