Differential, Removing and Installing

Differential, removing and installing

Note:





^ Adjustments are required when replacing components marked 1).

Secure final drive on a repair stand.

1 - Vent sleeve
^ With rubber valve
^ Installation position see Fig. 4.

2 - Final drive housing 1)

3 - Outer race for large taper roller bearing 1)





4 - Shim "S1"
^ Note thickness

5 - Cover for final drive 1)
^ With O-ring
^ Replace O-ring
^ Insert O-ring with oil

6 - TORX-screw - 25 Nm

7 - Seal, right

8 - Hex socket-head bolt - 25 Nm

9 - Flange shaft, right

10 - Oil filler plug - 35 Nm

11 - Differential with ring gear 1)

12 - Oil drain plug, 35 Nm

13 - Socket
^ Holds solenoid in position
^ Drive in onto stop

14 - Solenoid

15 - Outer race for small taper roller bearing 1)





16 - Shim "S2"
^ Note thickness

17 - Seal, left

18 - Flange shaft, left

19 - Hex socket-head bolt - 25 Nm

20 - Cap





Fig. 1 Secure final drive on repair stand





Fig. 2 Removing and installing flange shaft





Fig. 3 Press in cover until stop





Fig. 4 Installation position vent sleeve

The vent sleeve must protrude from the housing by 13 mm (dimension -a-) after being pressed in.

The slot in rubber valve is located longitudinally in direction of travel.

Removal
^ Rear final drive removed

Special tools, testers and auxiliary equipment required





^ Drip tray VAG 1306

- Clamp complete rear final drive into assembly bracket VW 540.
- Place drip tray underneath to collect oil.
- Drain gear oil.





- Remove left and right-hand flange shafts.
- To loosen the securing bolt, screw two bolts into flange shaft and counter-hold with a lever.
- Mark flange shafts (left and right) and pull out.
- Remove securing bolts from cover for final drive.
- Take cover for final drive off axle housing and remove differential.

Installing
Installation is in reverse order.
- Insert differential.
- Replace O-ring for cover for final drive and oil when installing.
- Install cover for final drive onto axle housing and using diagonal sequence tighten to 25 Nm.
- Fill space between sealing lip and dust lip with a thin layer of sealing grease G 052 128 A1.





- Insert flange shafts and tighten to 25 Nm.
- Top off gear oil in rear final drive and check oil level.