Differential, Disassembling and Assembling
Differential, disassembling and assembling, 02M/02Y, 5 & 6 Speed M/T, AWD
Special tools, testers and auxiliary items required
^ Transmission support VW 353
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 407
^ Punch VW 408 A
^ Thrust disc VW 412
Special tools, testers and auxiliary items required
^ Thrust piece 40-105
^ Thrust pad 3005
^ Tube 3259
^ Tube 3296
^ Press tool 3345
^ Torque wrench V.A.G 1332
Special tools, testers and auxiliary items required
^ Taper roller bearing puller V.A.G 1582
^ Attachment V.A.G 1582/6 A
^ - 1 - Internal extractor Kukko 21/7
^ - 2 - Puller Kukko 18/0
^ - 3 - Separating tool Kukko 17/1
^ - 4 - Support Kukko 22/2
Differential, assembly overview
Note:
^ Heat inner race/tapered roller bearing to 100°C before installing.
^ Replace both tapered roller bearings together.
^ Adjust differential when replacing tapered roller bearing, differential housing, transmission housing and clutch housing.
1 - Transmission housing
2 - Bolt
^ Replace
3 - Differential housing
^ Bolting on to final drive gear
4 - Gear wheel for final drive
^ Riveted in series
^ Pressing off
^ Installed position: Ground side faces bolting surface of differential housing
^ Heating to 100° C before installing
^ Setting on differential housing
^ Bolted
5 - Washer plate
6 - Nut, 40 Nm plus an additional 45° (1/8 turn)
7 - Clutch housing
8 - Adjustment shim
^ For differential
9 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in
10 - Inner race for tapered roller bearing
^ Pulling off
^ Pressing on
11 - Differential housing
^ With riveted gear for final drive
^ Drilling off rivet heads when replacing gear wheel for final drive
^ Securing gear for final drive with bolts
12 - Inner race for tapered roller bearing
^ Pulling off
^ Pressing on
13 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in
14 - Washer
^ 0.65 mm thick
15 - Connecting sleeve to bevel gear transfer case
^ Pressed onto differential housing
^ Pulling off and pressing on only with differential housing removed
^ Pulling off
^ Pressing on
16 - Seal
^ For right drive flange
^ Diameter is different on left and right sides
17 - Bevel gear transfer case
^ Removing and installing with transmission removed
18 - Hex bolt, 40 Nm plus an additional 45° (1/8 turn)
^ Replace
19 - Washer
20 - Conical head bolt, 25 Nm
21 - Right flanged shaft
22 - O-ring
^ Replace
23 - O-ring
^ Replace
24 - O-ring
^ Replace
25 - Large differential bevel gear
26 - Differential bevel gear axle
^ Driving out using drift
27 - Roll pin
^ For securing shaft for differential bevel gears
28 - Small differential bevel gear
29 - Threaded piece
30 - Thrust washer connection
^ Lubricate with transmission fluid before installing
31 - Circlip
^ Holds tapered ring, thrust washer and compression spring in position with flanged shaft removed
32 - Tapered ring
^ With grooves for thrust washer to engage
^ Installed position: cone to differential housing
33 - Thrust washer
^ Installed position: Collar to compression spring, braces to tapered ring
34 - Compression spring for flanged shaft
^ Installed behind flanged shaft
35 - Left flanged shaft
36 - Seal
^ For left flanged shaft
^ Diameter is different on left and right sides
^ Replace with transmission installed.
Pulling outer race/tapered roller bearing off clutch housing
A - Support Kukko 22/2
B - Internal puller 46 to 58 mm Kukko 21/7
Note: After pulling off, check shim for damage and replace if necessary.
Pressing in outer race/tapered roller bearing into clutch housing
- First, insert shim.
Pulling off inner races for tapered roller bearing
- Before attaching extractor, place Thrust piece 40-105 on differential housing.
Note: Pulling off both inner races/tapered roller bearing for differential housing is identical.
Pressing on inner races of tapered roller bearing
Note: Inner race/tapered roller bearing for transmission housing and clutch housing are pressed on using the same tools.
Pulling outer race/tapered roller bearing out of transmission housing
A - Support Kukko 22/2
B - Internal puller 46 to 58 mm Kukko 21/7
Pressing in tapered roller bearing outer race into transmission housing
- Support transmission housing directly beneath bearing mount using Press tool 3345.
Drilling out rivet heads
- Drill out rivet heads on countersunk side using 12 mm drill and drive out rivets using a drift.
Note: Clean differential before and after drilling and protect tapered roller bearing from drill shavings.
Pressing off gear wheel for final drive
- Place thrust piece 40-105 on differential housing.
Heat gear for final drive to approx. 100°C and install.
CAUTION! Wear protective gloves!
- When installing, guide gear for final drive with bolts - A - from repair set.
Bolt gear wheel for final drive - A - to differential housing - B -
Use special bolts - 1 - with washer plates - 2 - and nuts - 3 -.
Removing and installing roll pin for differential bevel gear axle
Removing:
- Cover inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.
- Drive out roll pin using a chisel, place chisel in surrounding groove to do so.
Installing:
- Drive in roll pin into differential housing until stop.
Installing small differential bevel gears
- Lubricate thrust washer connection with gear oil when inserting.
- Insert both large differential bevel gears and secure (e.g. with flanged shaft).
- Install small differential bevel gears at 180° from their final position and rotate into place.
- Press in differential bevel gear axle - arrow A - up to first small differential bevel gear.
- Insert threaded pieces - arrows B - in large differential bevel gears.
^ Installed position: Shoulder to differential bevel gear.
- Drive in differential bevel gear axle to final position and secure with rolling pin.
Pulling off connecting sleeve
A - Connecting sleeve
B - Puller Kukko 18/1
C - Separating tool 12 to 75 mm Kukko 17/1
Pressing on connecting sleeve - A - for bevel gear transfer case