Center Differential, Servicing
Center differential, servicing
Transmission installed
Special tools and equipment
^ VW401 thrust plate
^ VW412 punch
^ VW402 thrust plate
^ VW454 thrust tube
^ VW407 punch
^ 3021 sleeve
Special tools and equipment
^ 40-20 sleeve
^ 3118 press support
^ Item 3 Kukko 17/2 separating tool
WARNING: Do not run engine with the center differential removed or without gear oil and do not tow vehicle.
Notes:
^ Rules of cleanliness for working on automatic transmissions .
^ General repair notes .
The parts listed in the following illustration can be removed with the transmission installed.
1 - Socket head bolt - 25 Nm
2 - Output flange/driveshaft
3 - Seal
^ For output flange/driveshaft item 2 -
^ Always replace
4 - Bolt - 23 Nm
^ For housing cover -item 5 -
^ 4x
5 - Housing cover
^ With dampener
6 - O-ring
^ Coat with transmission fluid
7 - Snap ring
^ For ball bearing item 8 - on spur gear -1- item 9
8 - Grooved ball bearing
^ For spur gear -1- item 9
^ Pressing off
^ Pressing on
9 - Spur gear 1
^ For rear gear set
^ If damaged, only replace together with spur gear 2 -item 17-
^ To remove and install, pull out of center differential housing toward rear together with item 7 and item 8
10 Snap ring
^ For needle bearing item 11 -
11 - Needle bearing
^ For spur gear -1- item 9
^ Only remove for replacement
^ To replace, heat up transfer gear housing to approximately 100°C and drive out needle bearing toward rear using drift (Warning! Wear protective gloves)
^ Drive into stop using 30-21 sleeve
12 - Bolt - 23 Nm
^ Loosen or tighten in stages and in diagonal sequence
13 - Center differential housing
14 - Tension nut
^ For output flange/driveshaft item 2
15 - Needle bearing
^ For spur gear -2- item 17 -
^ Only remove for replacement
^ Always replace
16 - Snap ring For securing needle bearing -item 15 in center differential housing item 13
17 - Spur gear -2-
^ For rear gear set
^ If damaged, only replace together with spur gear -1- item 9
^ To remove and install, remove center differential housing and pull out together with item 18 and 23
18 - Grooved ball bearing
^ For spur gear -2- item 17
^ Pressing off
^ Pressing on
19 - Snap ring
^ For securing grooved ball bearing -item 18 - in center differential housing
20 - Washer
^ For grooved ball bearing -item 18 -
^ Before installing, clip on guide plate -item 21-
21 - Alignment plate
22 - Bolt - 10 Nm
23 - Snap ring
^ For securing grooved ball bearing -item 18 - on spur gear -2- item 17-
24 - Gasket
^ Always replace
25 - Torsion differential
^ If damaged replace as complete unit
^ Removing and installing
26 - Seal
^ Always replace
27 - Magnet
^ Removing and installing
28 - Bushing
^ 2x
29 - Breather
^ For transfer gear
^ With cap installed
^ Installation position: Without cover, breather must project 10 - 11 mm out of housing
30 - Bolt - 23 Nm
^ Observe tightening sequence
31 - Intermediate flange for front final drive
32 - Gasket
^ Always replace
33 - Bushing
34 - Drive pinion
^ For front final drive
^ Removing and installing
35 - Intermediate pinion For front final drive
^ Installation position: gear identification faces toward transfer gear
36 - Output pinion
^ For front final drive
^ Installation position: gear identification faces toward transfer gear
37 - Seal
^ Always replace
Fig. 1 Press off grooved ball bearing for spur gear 1:
A - Separating device 22-115 mm, e.g. Kukko 17/2 separating tool
Fig. 2 Press on grooved ball bearing for spur gear 1:
Fig. 3 Press off grooved ball bearing for spur gear 2:
A - Separating device 22-115 mm, e.g. Kukko 17/2 separating tool
Fig. 4 Press on grooved ball bearing for spur gear 2:
