Differential, Removing and Installing

Differential, removing and installing





Note:
^ General repair instructions.
^ Adjustments are required when replacing components marked 1) go to adjustment overview.

Secure final drive on a repair stand.
1 - Vent sleeve
^ With rubber valve
^ Installation position go to Fig. 4.

2 - Final drive housing 1)
^ Removing and installing drive pinion.

3 - Outer race for large taper roller bearing 1)
^ Removing and installing.





4 - Shim S1
^ Note thickness
^ Adjustment overview.

5 - Cover for final drive 1)
^ With O-ring
^ Replace O-ring
^ Insert O-ring with oil

6 - TORX-screw - 25 Nm





7 - Seal, right
^ Replacing.

8 - Hex socket-head bolt - 25 Nm
9 - Flange shaft, right
^ Removing and installing go to Fig. 2

10 - Oil filler plug - 35 Nm
^ Checking gear oil level in rear final drive

11 - Differential with ring gear 1)
^ Disassembling and assembling

12 - Oil drain plug, 35 Nm
13 - Socket
^ Holds solenoid in position
^ Drive in onto stop

14 - Solenoid
15 - Outer race for small taper roller bearing 1)
^ Removing and installing.





16 - Shim S2
^ Note thickness
^ Adjustment overview

17 - Seal, left
^ Replacing.

18 - Flange shaft, left
^ Removing and installing go to Fig. 2

19 - Hex socket-head bolt - 25 Nm
20 - Cap
^ Installing go to Fig. 3





Fig. 1 Secure final drive on repair stand





Fig. 2 Removing and installing flange shaft





Fig. 3 Press in cover until stop





Fig. 4 Installation position vent sleeve
The vent sleeve must protrude from the housing by 13 mm (dimension -a-) after being pressed in.
The slot in rubber valve is located longitudinally in direction of travel.

Removal
^ Rear final drive removed

Special tools, testers and auxiliary equipment required

Drip tray VAG 1306:

- Clamp complete rear final drive into assembly bracket VW 540.
- Place drip tray underneath to collect oil.
- Drain gear oil.





- Remove left and right-hand flange shafts.
- To loosen the securing bolt, screw two bolts into flange shaft and counter-hold with a lever.
- Mark flange shafts (left and right) and pull out.
- Remove securing bolts from cover for final drive.
- Take cover for final drive off axle housing and remove differential.

Installing
Installation is in reverse order.
- Insert differential.
- Replace O-ring for cover for final drive and oil when installing.
- Install cover for final drive onto axle housing and using diagonal sequence tighten to 25 Nm.
- Fill space between sealing lip and dust lip with a thin layer of sealing grease G052 128 A1.





- Insert flange shafts and tighten to 25 Nm.
- Top off gear oil in rear final drive and check oil level.