Removal/Installation
REMOVAL AND INSTALLATIONCAUTION:
^ If the pinion and the tapered roller bearing are to be reused after the repair, backlash and pinion shaft turning torque must be measured and noted before disassembling the final drive, refer to Ring, Pinion and Input Gear. Adjustments
^ These parts must be adjusted as closely as possible to the original settings during re-assembly (for quieter running and maximum service life).
NOTE:
^ The pinion does not have to be removed to remove and install the differential gear.
1. Sealing cap
- Always replace
- Drive in using wrench insert SW 30
2. Circlip
3. Drive flange
- Pulling off, refer to Fig. 1, below
- Installing, refer to Fig. 2, below
4. Drive flange oil seal
- Can be replaced with transaxle installed, refer to Transaxle Side Seals
- Remove using VW 681
- Driving in, refer to Fig. 3, below
5. Circlip
6. Grooved ball bearing
- Removing, refer to Fig. 4, below
- Installing, refer to Fig. 5, below
7. Cone ring
- Tapered shoulder (small diameter) points toward grooved hall bearing
8. Compression spring
9. Bolt
- Tighten to: 30 Nm (22 ft lb)
10. Drive flange
- Install along with compression spring, support ring and cone ring, refer to Fig. 6, below
11. Compression spring
12. Support ring
13. Cone ring
- Chamfer faces differential gear
14. Drive flange oil seal
- Can be replaced with trans. installed, refer to Transaxle Side Seals, A/T. Service and Repair
- Remove using VW 681
- Driving in, refer to Fig. 7, below
15. Bolt
- Tighten to: 25 Nm (18 ft lb)
16. Oil inspection bolt
- Tighten to: 25 Nm (18 ft lb)
17. Speedometer Vehicle Speed Sensor (VSS)
18. O-ring
- Always replace
19. Cover/differential gear
- If replaced, ring gear must be adjusted, refer to Ring and Pinion and Input Gear. Adjustments
20. O-ring
- Always replace
21. Drive gear
- For speedometer vehicle speed sensor
22. Differential
- Disassembling and assembling, refer to Differential Gear
- If replaced, ring gear must be adjusted, refer to , refer to Ring and Pinion and Input Gear. Adjustments
23. Bolt
- Tighten to: 10 Nm (84 inch lbs)
24. Breather cover
25. Gasket
26. Transmission housing
NOTE:
^ Install in reverse sequence.
^ Check final drive oil level with transmission installed page 39-1.
Fig. 1 Pulling off drive flange (right side)
A in illustration = Kukko 18-1 puller
- Remove sealing cap and circlip before pulling off drive flange.
Fig. 2 Installing drive flange (right side)
Fig. 3 Driving in drive flange oil seal (right side)
Fig. 4 Removing grooved ball bearing
NOTE: Circlip must already be removed.
- Insert hex bolt, M12 x 20, and washer in hole of output shaft drive flange.
- Mount jaws of VAG1582/10 between balls on inner race of grooved ball bearing.
- Pull out grooved ball bearing.
Fig. 5 Pressing in grooved ball bearing
NOTE: Press in along with cone ring and compression spring.
Fig. 6 Installing drive flange (left side)
NOTE: The lugs (2 in illustration) of the drive gear (vehicle speed sensor) must be engaged between the clips on the support ring (1 in illustration).
Fig. 7 Installing drive flange oil seal (left side)