Torsen Differential Cover, Removing and Installing
Torsen differential cover, removing and installing - 01J, Continuously Variable Transmission (CVT)
Special tools, testers and auxiliary items required
^ Seal remover T40014
^ Pressure stand T40099
^ Ice spray
^ Protective gloves
Removing:
^ Input shaft removed Refer to Input shaft, removing and installing.
- Pull oil pipe -arrow- upward and out to avoid damage.
- Check all 8 screws -arrows- on Pressure Stand T40099.
^ Screws must be installed flush to 25 Nm Assembly instructions for pressure stand T40099.
- Insert input shaft in pressure stand T40099.
- Rotate seal ring extractor T40014 by hand into shaft seal until tool has a good hold in the shaft seal. Then tighten puller with an open-end wrench.
- You can pull out shaft seal a short distance by installing rear bolt -arrow-.
- Re-tighten Seal ring extractor T40014 so that puller engages securely in shaft seal again and continue turning bolt to pull out shaft seal.
- Repeat procedure until shaft seal has been pulled out completely.
- Remove input shaft cover circlip -A-.
- Measure and note thickness of removed circlip.
Note:
^ When installing, circlip must be replaced with a new circlip of same thickness.
- Clean cover sealing surface -arrow-.
CAUTION!
Wear protective gloves!
The ice spray can reach temperatures under 0 ° Celsius which can freeze the skin without protective gloves.
- Cool hollow shaft -1- on inside of ball bearing -2- seat - arrow 2 - over opening - arrow 1 - of removed oil pipe with ice spray, for example.
Note:
^ Shaft represented in section here.
^ Shaft must be cooled so that ball bearing -2- can be pressed off more easily and not be damaged.
- Clean surface of pressure stand T40099.
- Insert input shaft in pressure stand T40099.
^ Input shaft sealing surface must be flush.
^ There must be no objects such as cable ties or dirt between input shaft sealing surfaces and surface of pressure stand T40099.
CAUTION!
Shavings or dirt damage cover sealing surfaces when pressed, cover must then be replaced.
- Also cool shaft from outside -arrow- with ice spray, for example.
Note:
^ Shaft must be cooled so that ball bearing can be pressed off more easily and not be damaged.
- Place input shaft together with pressure stand T40099 on hydraulic press thrust plate.
Note:
^ Pressure stand T40099 should lie on as much surface of hydraulic press as possible.
- Hold shaft from below and at the same time, press shaft out of cover with hydraulic press.
- Place input shaft on assembly tool T10219/1.
Note:
^ Ignore screwdriver and arrows.
Installing:
- Replace ball bearing in input shaft cover.
- Place input shaft cover on input shaft and press on by hand as far as possible.
- Place input shaft -B- on Thrust plate VW 401.
CAUTION!
Place input shaft straight and centered under hydraulic press thrust disc; otherwise input shaft can tip to the side when cover is pressed on.
- With hydraulic press, press input shaft cover -A- with Tube VW 416 B onto input shaft up to stop.
Input shaft cover circlip, installing
- When installing, circlip -A- must be replaced with a new circlip of same thickness.
Note:
^ Check for correct circlip seating.
Oil pipe, installing
- Check wear on transmission components.
- Replace O-ring on oil pipe -2-.
^ The oil pipe is pressed into the input shaft with the O-ring -2-.
^ Oil pipe must engage noticeably, rotor blades -arrow A- on oil pipe must lie completely in input shaft.
- Press oil pipe -arrow- down into input shaft to stop.
^ If oil pipe is inserted completely, the dimension from its end to the input shaft is approx. 11.5 mm.
If dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.
If dimension is larger, it is not pushed in far enough.
CAUTION!
^ Input shaft must not be set down on the projecting oil pipe -arrow- otherwise it will be damaged.
^ If the oil pipe is damaged, starting problems or a transmission malfunction will result.