Differential, Disassembling and Assembling
Differential, disassembling and assembling
The following special tools and testing devices are required:
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 407
^ Thrust disc VW 412
^ Needle bearing drift VW 295
^ Punch VW 408 A
^ Thrust pad VW 442
^ Sleeve 40-21
^ Thrust piece 40-105
^ Thrust plate 2050
^ Drift 3138
^ Two-arm puller Kukko 44/2
^ Taper roller bearing extractor V.A.G 1582
^ V.A.G 1582/6
Note:
^ Secure final drive on a repair stand.
^ Replace both taper roller bearings together.
^ When replacing the parts marked with 1) adjustment work is required.
1 - Cover for final drive 1)
2 - O-ring
^ Replace
^ Insert with oil
3 - Final drive housing 1)
4 - Shim "S1"
^ Note thickness
5 - Outer race for small taper roller bearing 1)
^ Tapping out see Fig. 1
^ Pressing in see Fig. 2
6 - Inner race for small taper roller bearing 1)
^ Pulling off see Fig. 3
^ Pressing on see Fig. 4
7 - Bolt - 60 Nm plus an additional 45° 1/4 turn
^ Replace
^ Lightly tighten bolts then tighten diagonally to specified torque.
8 - Differential housing 1)
9 - Ring gear 1)
^ Paired with pinion shaft (final drive set)
^ Drive off housing with a drift see Fig. 9
^ Install to differential housing see Fig. 10
10 - Spring pin
^ For securing shaft for bevel gears
^ Drive in flush
11 - Inner race for large taper roller bearing 1)
^ Pulling off see Fig. 5
^ Pressing on see Fig. 6
12 - Outer race for large taper roller bearing 1)
^ Tapping out see Fig. 7
^ Pressing in see Fig. 8
13 - Shim "S2"
^ Note thickness
14 - Threaded piece
15 - Large bevel gear
^ Installing see Fig. 11
^ Adjusting see Fig. 12
16 - Small bevel gear
^ Installing see Fig. 11
17 - Shaft for planet wheels
^ Drive out with drift
18 - Adjustment shim
^ Redefine thickness see Fig. 12
19 - Thrust washer
Check for cracks
Fig. 1 Driving small taper roller bearing outer race out of cover
- After removing check shims for damage.
Fig. 2 Pressing in taper roller bearing outer race small until stop into housing
Fig. 3 Pulling off inner race for small taper roller bearing
A - Two arm puller, e.g. Kukko 44/2
Fig. 4 Pressing on small taper roller bearing inner race
WARNING! Wear protective gloves!
- Heat inner race to approx. 100° C, position and push to final position.
Fig. 5 Pulling off inner race for large taper roller bearing
- Install thrust plate 40-105 onto differential housing before installing puller.
Fig. 6 Pressing on large taper roller bearing inner race
WARNING! Wear protective gloves!
- Heat inner race to approx. 100° C, position and push to final position.
Fig. 7 Driving out outer race for large taper roller bearing out of cover
- After removing check shims for damage.
Fig. 8 Pressing in outer race for large taper roller bearing into cover
Fig. 9 Driving ring gear off housing
Fig. 10 Installing ring gear
WARNING! Wear protective gloves!
- Locate ring gear guide with centering pins -A- (self-produced) when mounting.
- Heat ring gear to approx. 100° C and position.
Fig. 11 Installing small bevel gears
- If large bevel gears have been replaced, measure and select new shims see Fig. 12.
- Insert large bevel gears with recalibrated shims.
- Insert small bevel gears spaced 180° apart, and then rotate into place -arrow-.
- Insert washers and align.
- Insert threaded pieces.
- Drive small bevel gear shaft into final position and secure.
Fig. 12 Adjusting differential bevel gears
- Insert large bevel gears with thinnest shims (0.5 mm).
- Insert small bevel gears at a 180° offset with thrust washers.
Note:
^ Do not now interchange bevel gears and thrust washers.
- Drive in shaft for bevel gears.
- Press small bevel gears outward.
- Press large bevel gears in direction of -arrow- and check play.
- Ascertain the thickest - just fitting - shim for large bevel gears on each side.
- Select required shims from table. Part numbers
The following shims are available:
Note:
^ The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the differential bevel gears -arrow-.