Disassembling and Assembling
Differential, disassembling and assembling, 02M/02Y, 5 & 6 Speed M/T, AWD
Special tools and equipment
^ VW 353 transmission support
^ VW 401 pressure plate
^ VW 402 pressure plate
^ VW 407 punch
^ VW 408 A punch
^ VW 412 thrust disc
Special tools and equipment
^ 40-105 thrust piece
^ 3005 thrust pad
^ 3259 tube
^ 3296 tube
^ 3345 press tool
^ VAG1332 torque wrench
Special tools and equipment
^ VAG1582 tapered roller bearing puller
^ VAG1582/6 gripping piece
^ 1 - Kukko 21/7 puller
^ 2 - Kukko 18/0 puller unit
^ 3 - Kukko 17/1 separating unit
^ 4 - Kukko 22/2 support
Notes:
^ Heat inner ring/tapered roller bearing to 100°C (212°F) before installation.
^ Replace tapered roller bearings together.
^ Adjust differential when replacing tapered roller bearings, differential housing, transmission housing and clutch housing.
1 - Transmission housing
2 - Bolt
3 - Differential housing
^ Bolt to pinion for final drive
4 - Pinion for final drive
^ Riveted in series
^ Press off => Fig. 8
^ Installation position: ground surface points in direction of bolting surface of differential housing
^ Heat to 100°C before installation
^ Set onto differential housing => Fig. 9
^ Bolted => Fig. 10
5 - Backing plate
6 - Nut, 40 Nm + additional 45°
7 - Clutch housing
8 - Adjustment shim
^ For differential
9 - Tapered roller bearing outer race
^ Pulling off => Fig. 5
^ Pressing in => Fig. 6
10 - Tapered roller bearing inner race
^ Pulling off => Fig. 3
^ Pressing on => Fig. 4
11 - Differential housing
^ With pinion gear for final drive riveted on
^ Drill out rivet heads for replacement of pinion gear for final drive => Fig. 7
^ Secure pinion gear for final drive with bolts => Fig. 10
12 - Tapered roller bearing inner race
^ Pulling off => Fig. 3
^ Pressing on => Fig. 4
13 - Tapered roller bearing outer race
^ Pulling off => Fig. 1
^ Pressing in => Fig. 2
14 - Disk
^ Always 0.65 mm thickness
15 - Connection sleeve for angled transmission
^ Pressed onto differential housing
^ Only pull off and press on with differential housing removed
^ Pulling off => Fig. 13
^ Pressing on => Fig. 14
16 - Sealing washer
^ For right drive flange
^ Left and right have different diameters
17 - Angled transmission
18 - Hex bolt
^ 40 Nm + additional 45°
19 - Disc
20 - Tapered bolt, 25 Nm
^ Bolt to threaded piece (-29-)
21 - Drive flange, right
22 - O-ring
^ Always replace
23 - O-ring
^ Always replace
24 - O-ring
^ Always replace
25 - Large differential bevel gear
^ Installing => Fig. 12
26 - Differential bevel gear axle
^ Drive out with drift
^ Installing => Fig. 12
27 - Roll pin
^ For securing axle for differential bevel gears
^ Removing and installing => Fig. 11
28 - Small differential bevel gear
^ Installing => Fig. 12
29 - Threaded piece
^ Installing => Fig. 12
30 - Thrust plate connection
^ Install with transmission oil
31 - Securing ring
^ Holds tapered ring, thrust plate and pressure spring in position with drive flange removed
32 - Tapered ring
^ With grooves for thrust plate engagement
^ Installation position: taper for differential housing
33 - Thrust plate
^ Installation position: collar to pressure spring, ribs to threaded ring
34 - Pressure spring for drive flange
^ Installed behind drive flanges.
35 - Left drive flange
36 - Seal
^ For left drive flange
^ Left and right have different diameters
Fig. 1 Removing tapered roller bearing outer race from clutch housing
A - Support, i.e. Kukko 22/2
B - Puller 46...58 mm, i.e. Kukko 21/7
Note: After pulling out, check shim for damage and replace if necessary.
Fig. 2 Installing tapered roller bearing outer race on clutch housing
- Insert shim before.
Fig. 3 Removing tapered roller bearing inner race
- Place 40-105 pressure actuator onto differential housing before installing puller.
Note: Removing of both tapered roller bearing inner races from differential housing is identical.
Fig. 4 Installing tapered roller bearing inner race
Note: Tapered roller bearing inner races for transmission housing and clutch housing are pressed on using the same pressing tools.
Fig. 5 Removing tapered roller bearing outer race from transmission housing
A - Support, i.e. Kukko 22/2
B - Inner puller 46...58 mm, i.e. Kukko 21/7
Fig. 6 Installing tapered roller bearing outer race into transmission housing
- Support transmission housing with 3345 press tool directly below bearing support.
Fig. 7 Drilling out rivet heads
- Drill out rivet heads on countersunk side using a 12 mm drill bit and drive out rivet using a mandrel.
Note: Clean differential before and after drilling out, protect tapered roller bearings from drilling shavings.
Fig. 8 Removing final drive pinion gear
- Set 40-105 pressure actuator onto differential housing.
Fig. 9 Heat up final drive pinion gear to approx. 100°C and install
- Guide final drive pinion gear with bolts -A- from repair set.
Fig. 10 Bolt final drive pinion gear to approx. -A- to differential housing -B-
Use special bolts -1- with mounting plates - 2 - and nuts -3-.
Fig. 11 Removing and installing roll pin for differential bevel gear axle
Removing
- Cover tapered roller bearing inner race to avoid possible damage and intrusion of shavings.
- Drive out roll pin using mandrel by inserting in surrounding notch.
Installing
- Drive into differential housing until stop.
Fig. 12 Installing differential bevel gears
- Insert thrust plate connection with transmission oil.
- Insert and secure both large differential bevel gears (i.e. with drive flange).
- Install small differential bevel gears 180° from their final position and pivot into place.
- Drive in differential bevel gear shaft (arrow -A-) to first small differential bevel gear.
- Insert threaded pieces (arrows -B-) in large differential bevel gears Installation position: shoulder to differential bevel gear.
- Drive in differential bevel gear shaft to end position and secure with roll pin.
Fig. 13 Removing connecting sleeve
A - Connecting sleeve
B - Puller, i.e. Kukko 18/1
C - Separator 12...75 mm, i.e. Kukko 17/1
Fig. 14 Pressing on connecting sleeve -A- for angled transmission