Disassembling and Assembling

Differential, disassembling and assembling
Special tools and workshop equipment required





- VW 401 Press plate
- VW 402 Press plate
- VW 407 Press tool
- VW 408 A Press tool
- VW 447 H Press plate
- VW 447 i Thrust plate





- VW 472/1 Thrust piece
- 2050 Thrust piece
- 3138 Driver
- 3144 Sleeve
- 3296 Tube
- VAG 1332 Torque wrench





- VW 459 Installing and removing tool
- 1 - Kukko 21/7 Internal puller
- 3 - Kukko 204/2 Puller
- 4 - Kukko 22/2 Counter support
- Kukko 44-2 Two arm puller

Notes:
- Heat taper roller bearing inner race to 100°C before installing.
- Always replace both taper roller bearings together as a set.
- If taper roller bearings, differential housing, final drive cover, ring gear or pinion or the transmission housing is replaced, the differential must be adjusted.





1. Transmission housing
2. Shim S2
- Note thickness
3. Taper roller bearing outer race
- Pulling out see Fig. 1
- Pressing in see Fig. 2
4. Taper roller bearing inner race
- Pulling off see Fig. 3
- Pressing on see Fig. 4
5. Ring gear
- Is mated to pinion shaft (pinion set)
- Allocate according to transmission code letters using parts catalog
- Drive off with a drift see Fig. 10
- Fit to differential cage see Fig. 11
6. Differential cage
- Modification: adapted on cover side to enlarged taper roller bearing see Fig. 8
- Allocate using parts catalog
7. Hexagon bolt, 60 Nm then turn 45° further
- Always replace
- Lightly tighten bolts then tighten diagonally to correct torque
8. Taper roller bearing inner race
- Pulling off see Fig. 5
- Pressing on see Fig. 4
- Modification: adapted on cover side to enlarged taper roller bearing see Fig. 8
- Allocate using parts catalog
9. Speedometer drive wheel
10. Taper roller bearing outer race
- Knocking out see Fig. 6
- Pressing in see Fig. 7
- Modification: adapted on cover side to enlarged taper roller bearing see Fig. 8
^ Allocate using parts catalog
- Pressing in outer race for large taper roller bearing see Fig. 9
11. Shim S1
- Note thickness
- Modification :adapted on cover side to enlarged taper roller bearing see Fig. 8
- Allocate using parts catalog
12. Cover
- For final drive
- Modification: adapted on cover side to enlarged taper roller bearing see Fig. 8
13. Sun wheel
- Installing see Fig. 13
14. Planet pinion axis shaft
- Knock out with drift
15. Spring pin
- For securing planet pinion axis shaft
- Removing and installing spring pin with circumferential groove see Fig. 12
16. Planet pinion
- Installing see Fig. 13
17. One-piece thrust washer
- Coat with transmission oil when installing





Fig. 1 Pulling taper roller bearing outer race out of transmission housing
A - Counter support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
- After removing check shims for damage.





Fig. 2 Pressing taper roller bearing outer race into transmission housing
- Press piece VW 472/1 is fitted with the cone in the outer race.
- Support transmission housing with VW 459/2 directly below bearing mounting.





Fig. 3 Pulling off taper roller bearing inner race
A- Commercially available two arm puller, e.g. Kukko 44/2 or Kukko 20/10





Fig. 4 Pressing on taper roller bearing inner race

Note: The taper roller bearing inner races for transmission housing and cover are pressed on with the same press tools.





Fig. 5 Pulling off taper roller bearing inner race
A - Commercially available two arm puller, e.g. Kukko 204/2





Fig. 6 Knocking taper roller bearing outer race out of cover
- Turn webs -A- and -B- out until they sit on the outer race within the recess in transmission.
- After removing check shims for damage.





Fig. 7 Pressing taper roller bearing outer race into cover
- Press piece VW 472/1 is fitted with the cone in the outer race.





Fig. 8 Large taper roller bearing on cover side for final drive
- From transmission build date 17.08.8 in conjunction with the 1.9 ltr. - 85 kW Turbo Diesel engine.
- From transmission build date 11019 in all transmissions.
The following components have been changed:
1. Differential housing
2. Taper roller bearing inner race
3. Taper roller bearing outer race
4. Shim "S1"
5. Final drive cover





Fig. 9 Pressing outer race for large taper roller bearing into cover
- To press outer race of taper roller bearing into cover, use thrust pad 2050.





Fig. 10 Driving ring gear off housing





Fig. 11 Heating ring gear to approx. 100°C and installing
- When fitting ring gear, guide with centralizing pins -A- (local manufacture) Observe work safety regulations.





Fig. 12 Removing and installing spring pin with circumferential groove

Removing
- Pull out spring pin with side cutting pliers.

Installing
- Drive in spring pin as far as the stop.





Fig. 13 Installing sun wheels and planet pinions
- Lubricate one-piece thrust washer with transmission oil and install.
- Insert sun wheels.
- Insert planet pinions turned through 180° and pivot into position (arrow).
- Drive planet pinion shaft into final position and secure.