Torsion Differential Housing, Servicing, and Torsion Differential, Removing and Installing

Torsion differential housing, servicing, and Torsion differential, removing and installing





Special tools and workshop equipment required
^ VW 401 Pressure plate
^ VW 402 Pressure plate
^ VW 407 Press tool
^ VW 412 Press tool
^ VW 416 B Tubular section
^ VW 421 Tubular section





^ VW 439 Guide section
^ VW 519 Tubular section
^ VW 681 Extractor lever
^ 40-21 Sleeve
^ 2040 Tubular section
^ 3002 Pressure piece

Special tools, testers and other items required





^ VW 771/15 from universal tools VW 771





^ Separating tool Kukko 17/2
^ Internal puller Kukko 21/4





1 - Transmission cover
2 - Spring
3 - Front needle bearing
^ Extracting
^ Installation position
^ Pressing in
4 - Torsion differential
^ Do not disassemble
^ Press out after removing flange shaft
^ Replace if damaged
^ Pressing in
5 - Rear needle bearing
^ Extracting
^ Installation position
^ Pressing in
6 - Ball bearing
^ For Torsion differential Pressing off
^ Pressing on
7 - Circlip
8 - Circlip
^ Remove and install together with drive flange
9 - Ball bearing
^ For drive flange
^ Pressing out
^ Pressing in
10 - Torsion differential housing
^ For Torsion differential
11 - Circlip
12 - Sealing cap
^ Removing
13 - O-ring
^ Always replace
^ Install with grease
14 - TORX bolt - 22 Nm
15 - Oil seal
^ Extract with extractor lever VW 681
^ Driving in
16 - Dampener
17 - Circlip
18 - TORX bolt - 35 Nm
^ Self-locking
^ Always replace
19 - Drive flange
^ Removing and installing

Fig. 1 Removing sealing cap:

- Remove circlip -A-.
- Install an M8 bolt into threaded hole of sealing cap -B-.
- Pull out sealing cap -B- with bolt.

Fig. 2 Removing and installing drive flange:

- Expand circlip and pull out drive flange.
- When installing drive flange circlip must be installed at the same time.
- Circlip must be properly positioned in groove.

Fig. 3 Pressing out Torsion differential:

- Place pressure piece 3002 through hole (arrow) directly onto Torsion differential.

Fig. 4 Pressing off ball bearing of Torsion differential:

A - Separating tool 22 to 115 mm, e.g. Kukko 17/2

Fig. 5 Pressing ball bearing onto Torsion differential:

- Press on ball bearing as far as it will go.

Fig. 6 Pressing out ball bearing for drive flange:

- Remove circlip before pressing out.

Fig. 7 Pressing in ball bearing for drive flange:

- Install circlip after pressing in.

Fig. 8 Extracting needle bearing:

A - Internal puller, e. g. Kukko 21/4, 22 to 28 mm
- Both needle bearings in Torsion differential are extracted using the same internal puller.

Fig. 9 Installation position of front needle bearing:

^ Dimension a = 32.5 mm

Fig. 10 Installation position of rear needle bearing:

^ Dimension a = 14 mm

Fig.11 Pressing in needle bearing:

- Both needle bearings in Torsion differential are pressed in using the same special tool.

Fig. 12 Pressing in Torsion differential:

Fig. 13 Driving in oil seal:

- Slightly oil circumference of oil seal.
^ Installation position: 2 mm below surface of housing

- Fill space between sealing lip and dust lip with sealing grease G 052 128 A1.