Disassembly

Differential Assembly Removal





- Mount final drive to repair stand, and drain transmission oil





- Remove axle flange
^ A = 2 M8 x 30 hex bolts through slots in joint flange





NOTE: Before starting repair work (which does not require final drive to be adjusted) mark position of adjusting rings on transmission housing. Measure depth to which they are installed with VW 382/7 and record readings
^ Scribe left side (ring gear side) with one mark (arrow)
^ Scribe right side with two marks





- Remove adjusting rings





- Remove differential assembly





Final Drive Housing Disassembly
- Remove output housing bolts
- Remove housing
- Remove spacer ring and viscous coupling
- Drive out pin for speedometer drive
- Pull out speedometer drive





- Remove retaining ring





- Drill an additional 9.0 mm (0.35 in) diameter hole in bracket VW 457/2





- Push out pinion
- Fasten VW 457 with two M8 x 20 bolts
- Remove shim S3 and note thickness





- Mount support to flange and remove hex nut





- Remove flange, use two-armed extractor it necessary
- Remove flange shaft





- Remove needle bearing from flange shaft
^ A = Puller, e.g. Kukko 22-1
^ B = Inner extractor 12-14.5 mm, e.g. Kukko 21/1
- Pry seal out from cover
- Remove seals for outer and inner ball bearing





- Remove both ball bearings
^ A = Puller, e.g. 22-2
^ B = Inner extractor, 30-37 mm, e.g. Kukko 21/5





Pinion Disassembly





- Remove grooved nut at final drive with viscous coupling





- Remove pinion bearing