Differential

Differential

Special tools, testers and auxiliary items required

• Pressure Plate (VW 402)

• Punch (VW 408 A)

• Punch (VW 412)

• Transmission with right stub shaft: Thrust Piece (VW 473)

• Thrust Piece (40 - 105)

• Thrust Piece (3005)

• Sleeve (VW 415 A) Transmission with right flange shaft

• Tube (3259)

• Tube (3296)

• Tube For Wheel Bearing (3345)

• Taper Roller Bearing Puller (V.A.G 1582)

• Attachment (V.A.G 1582/6A)

• Internal Puller 46 to 58 mm (Kukko 21/7)

• Puller (Kukko 18/1)

• Separating Tool 12 to 75 mm (Kukko 17/1)

• Counter-Support (Kukko 22/2)

Pulling Outer Race of Tapered Roller Bearing Out of Clutch Housing





A Counter Support (Kukko 22/2)
B Internal Puller 46 to 58 mm (Kukko 21/7)

• After removing, check the shim for damage and replace if necessary.

Pressing Outer Race for Tapered Roller Bearing Into Clutch Housing





- Install the shim first.

• Shim installation position: the shoulder on inner diameter points toward sealing ring

Pulling Off Inner Race for Tapered Roller Bearing





- Before assembling puller, set the Thrust Piece (40 - 105) onto the differential housing.

Pressing On Tapered Roller Bearing Inner Race






Wear protective gloves!

- Heat inner race of tapered roller bearing to 100 °C / 212 °F before pressing on.

Pulling Off Inner race for Tapered Roller Bearing





A Puller (Kukko 18/1)
B Separating Device 12 to 75 mm (Kukko 17/1)

Transmission with Right Stub Shaft: Pressing On Tapered Roller Bearing Inner Race





- Place the Thrust Piece (VW 473) , with the smaller outer diameter, onto the inner race for tapered roller bearing.

• It must be possible to lightly rotate the cage with the tapered rollers when pressing in

Transmission with Right Flange Shaft: Pressing On Inner Race/Tapered Roller Bearing





• It must be possible to lightly rotate the cage with the tapered rollers when pressing in

Pulling Outer Race for Tapered Roller Bearing Out of Transmission Housing





A Counter Support (Kukko 22/2)
B Internal Puller 46 to 58 mm (Kukko 21/7)

Pressing Outer Race for Tapered Roller Bearing into Transmission Housing





- Support the transmission housing with the Press Tool (3345) directly under the bearing mount.

Removing and Installing Roll Pin for Differential Bevel Gear Axle





Removing

- Cover inner race for tapered roller bearing to prevent possible damage and entry of shavings.

- Drive out spring pin with chisel, inserting chisel into circumferential groove.

Installing

- Drive the spring pin into the differential housing up to the stop.

Installing the Differential Bevel Gears





- Insert the thrust washer union with gear oil.

- Install both sun wheels and secure (for example with flanged shaft).

- Insert the small differential planetary gears 180° offset and pivot them into position.

- Press the differential gear axle - arrow A - up to the first small differential gear.

- Insert threaded pieces - arrow B - into the large differential planetary gears.

• Installation position: shoulder to the differential gear.

- Drive differential planetary gear axle into final position and secure with spring pin.