Differential

Differential

Special tools, testers and auxiliary items required

• Slide Hammer (VW 771)

• Socket SW 27 (3257)

• Torque Wrench (V.A.G 1331)

• - 1 - Internal Puller (Kukko 21/5 )

• Removal and installation is also possible with transmission installed.

• Differential can be removed and installed without removing shifter, input shaft, pinion/hollow shaft and transmission cover. The removal of the above-mentioned parts is necessary when the differential must be adjusted.

• Check the polygon bearings for damage.

• The polygon bearings can only be replaced together with the flange shaft.

• If the polygon bearings do not run smoothly with the flange shaft removed, this does indicate that the bearings are faulty. A test for noisy bearings can only be performed with the bearings installed.

• A spacer ring is installed between the polygon bearing and differential pinion for drive flanges with a spline diameter of 30 mm. Refer to => [ Flange Shaft Assembly ] , - item 4 -.

• Adjustments are required when replacing components marked with 1). List of adjustments. Refer to => [ Adjustment Overview ] Adjustment Overview.





1 Transmission housing 1)

2 Oil seal

• Removing left, refer to => [ Removing Left Flange Shaft Seal ]

• Installing left, refer to => [ Left Flange Shaft Sealing Ring, Installing ]

• removing right, refer to => [ Removing the Right Flange Shaft Seal ]

• Installing right, refer to => [ Right Flange Shaft Sealing Ring, Installing ]

3 Securing ring

• Replace

• Removing and installing, refer to => [ Removing and Installing Securing Ring ]

4 Spacer ring

• Inserted only in conjunction with flange shafts with 30 mm spline diameter

• Remove with 30 to 37 mm internal puller, for example, (Kukko 21/5)

• Installing, refer to => [ Installing the Spacer Ring ]

5 Flange shaft

• Removing left, refer to => [ Left Flange Shaft, Removing ]

• Removing right, refer to => [ Removing Flange Shaft (right side) ]

• Driving in with drift (VW 295)

• Flange shaft assembly, refer to => [ Flange Shaft Assembly ]

6 Differential with ring gear1)

• Disassembling and assembling, refer to => [ Differential ] Differential

7 O-Ring

• Always replace

• Coat with transmission fluid

8 Final drive cover1)

9 Torx(R) bolt, 20 Nm plus an additional 90° turn

Left Flange Shaft, Removing





- Remove left flange shaft by fastening Puller ( T10037) to differential cover - arrow -.

Removing Flange Shaft (right side)





- Remove right flange shaft by fastening Puller ( T10037) to transmission housing - arrow -.

Removing and Installing Securing Ring





- Clamp flange shaft in vise, using jaw protectors. Press previous circlip out of flange shaft grooved with new circlip - A -.

Installing the Spacer Ring





- Install the spacer ring all the way without bending it.

Flange Shaft Assembly





1. Flange shaft

2. Needle bearing (polygon bearing)

3. Spacer ring

4. Spacer ring - also installed with spline diameter of 30 mm

5. Securing ring

• Needle bearings (polygon bearings) are difficult to move with flange shaft removed. This is no indication of faulty bearings.

Removing Left Flange Shaft Seal





- Pry out flange shaft seal using a lever.

Left Flange Shaft Sealing Ring, Installing





- Lightly oil the outer circumference of the new seal.

- Drive in new flange shaft sealing ring with Drift (2062) without tilting seal.

• Drive-in depth: 5.50 ± 0.15 mm under surface of cover.

• Fill area between sealing lip and dust lip halfway with Sealing Grease (G 052 128 A1).

- Drive in flange shaft using Centering Mandrel ( VW 295).

Removing the Right Flange Shaft Seal





- Pry out flange shaft seal - arrow - using a lever.

Right Flange Shaft Sealing Ring, Installing





- Lightly oil the outer circumference of the new seal.

- Drive in new flange shaft sealing ring with Drift (2062) without tilting seal.

• Drive-in depth: 5.50 ± 0.15 mm under surface of cover.

- Fill area between sealing lip and dust lip halfway with Sealing Grease (G 052 128 A1).