Differential, Disassembling and Assembling
Differential, disassembling and assembling
Special tools and workshop equipment required
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 408 A Press tool
^ VW 447 H Thrust disk
^ VW 447 i Thrust disk
Special tools and workshop equipment required
^ VW 472/1 Thrust piece
^ 2050 Thrust piece
^ 3138 Drift
^ 3144 Sleeve
^ 3296 Tube
^ VAG 1332 Torque wrench
Special tools and workshop equipment required
^ VW 459 Installation and removal tool
^ 1 - Kukko 21/7 Internal puller
^ 3 - Kukko 204/2 Puller
^ 4 - Kukko 22/2 Counter-support
^ Kukko 44-2 Two-arm puller
Note:
^ Removing and installing differential.
^ Replace both tapered roller bearings.
^ Adjustments are required when replacing components marked 1).
1 - Transmission housing
2 - Shim S2
^ Note thickness
^ Adjustment overview
3 - Outer race for right tapered roller bearing
^ Pulling out
^ Pressing in
4 - Inner race for right tapered roller bearing
^ Pulling off
^ Pressing on
5 - Ring gear 1)
^ Paired with drive pinion (final drive set)
^ Select according to transmission code letters from Parts Catalog
^ With a mandrel drive off housing
^ Install to differential housing
6 - Differential housing 1)
^ Select according to transmission code letters from Parts Catalog
^ Allocation
go to Parts Catalog
7 - Bolt - 60 Nm + turn 45° further
^ Always replace
^ Lightly tighten bolts then tighten diagonally to specified torque.
8 - Inner race for left tapered roller bearing
^ Pulling off
^ Pressing on
go to Parts Catalog
9 - Speedometer drive wheel
^ Removing and installing
^ Carefully install the drive wheel onto the differential, make sure that it is kept straight. The drive wheel can break using excessive force
10 - Outer race for left tapered roller bearing
^ Tapping out
^ Pressing in
^ Allocation
go to Parts Catalog
11 - Shim S1
^ Note thickness
^ Adjustment overview
12 - Cover for final drive 1)
^ Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces
13 - Large differential bevel gear
^ Installing
14 - Shaft for bevel gears
^ Remove spring sleeve knocking out with drift
15 - Spring pin
^ For securing shaft for bevel gears
^ With annular groove: Removing and installing
^ Without annular groove: Drive out with mandrel
16 - Small differential bevel gear
^ Installing
17 - One-piece thrust washer
^ When installing coat with transmission oil
Fig. 1 Extracting tapered roller bearing outer race from transmission housing:
A - Counter support, e.g. Kukko 22/2
B - Internal puller 46... 58 mm, e.g. Kukko 21/7
- Check shims for damage after removing.
Fig. 2 Pressing tapered roller bearing outer race into transmission housing:
- Install thrust pad VW 472/1 with taper in outer race.
- Support transmission directly beneath bearing support with VW 459/2.
Fig. 3 Pulling off inner race for right tapered roller bearing:
A - Available two-arm puller, e.g. Kukko 44/2 or Kukko 20/10
Note: In the differential housing there is a slot in the bearing seat for applying puller -A-.
Fig. 4 Pressing on inner race for right tapered roller bearing:
WARNING: Wear protective gloves.
- Heat inner race to approximately 100°C, and push to final position.
Fig. 5 Pulling off inner race for left tapered roller bearing:
A - Two arm puller, e.g. Kukko 204/2
Note: In the differential housing there is a slot in the bearing seat for applying puller -A-.
Fig. 6 Installing inner race for left tapered roller bearing:
Attention: Wear protective gloves.
-^ Heat inner race to approximately 100°C, and push to final position.
Fig. 7 Driving out outer race for left tapered roller bearing out of cover:
- Turn webs -A- and -B- out until they sit on outer race within recess in transmission.
- Check shims for damage after removing.
Fig. 8 Driving outer race for left tapered roller bearing into cover:
- Use thrust piece 2050 to press outer race for left tapered roller bearing into cover.
- Install thrust piece 2050 with taper in outer race.
Fig. 9 Driving ring gear off housing:
Fig.10 Heat the ring gear to approximately 100 Degree C and position:
WARNING: Wear protective gloves.
- Install ring gear guide on centering pins -A- (locally made).
- Allow ring gear to cool off slightly before inserting bolts. Then tighten to specified torque.
Fig. 11 Installing bevel gears:
- Lubricate one-piece thrust washer with transmission oil and install.
- Insert large differential bevel gears.
^ Insert small differential bevel gears at 180° from their final position and rotate into place -arrow-.
^ Drive in differential bevel gear shaft into final position and secure.
Fig. 12 Removing and installing spring sleeve:
Removing
- Using side-cutting pliers pull out spring sleeve with annular groove.
- Using a mandrel drive out from behind the spring sleeve without annular groove.
Installing
- Drive in spring sleeve to stop.