Torsen Housing, Disassembling and Assembling
Torsen housing, disassembling and assembling, 02X, 6-Speed Four-Wheel Drive M/T
Special tools, testers and auxiliary items required
^ Thrust plate VW401
^ Thrust plate VW402
^ Punch VW408A
^ Thrust disc VW412
^ Thrust tube VW454
^ Arbor thrust piece VW554
Special tools, testers and auxiliary items required
^ Punch 2005
^ Thrust piece 2050
^ Drift sleeve 30 - 100
^ Torque wrench V.A.G 1331
^ Shim 016311391A
^ Locking fluid AMV 185 101 A1
^ Sealing grease G 052 128 A1
1 - Flange shaft
^ Without vibration damper
^ Pressing out
^ Pressing in
2 - Needle bearing
^ Pull out of flange shaft using internal puller Kukko 21/1 and counter-support Kukko 22/1.
^ Press into flange shaft as far as it will go using punch VW 408 A.
3 - Bolt - 15 Nm plus an additional 90° 1/4 turn
^ For vibration damper
^ 3x
^ Apply locking fluid AMV 185 101 A1 when installing
4 - Vibration damper
^ Not installed on all versions
^ Select correct version according to color coding - arrow - or transmission code
5 - Oil seal
^ Prying out
^ Preparing for installation
^ Driving in
6 - Torsen housing
7 - Oil collector
^ Insert in hole on transmission cover
8 - Circlip
^ For flange shaft
^ Installation position
9 - Circlip
^ For ball bearing and sleeve
^ Installation position
10 - Sleeve
11 - Ball bearing
^ For flange shaft
^ Pressing out
^ Pressing in
12 - Flange shaft with vibration damper
^ Only replace as complete unit
^ Pressing out
^ Pressing in
Pressing out flange shaft
- Before pressing out flange shaft remove circlip from flange shaft
- Position Torsen housing in such a way that the flange shaft does not make contact with thrust plates VW 401 and thrust plates VW 402 when it is pressed out.
Pressing in flange shaft
- Before pressing in flange shaft, tighten vibration damper (if installed).
- Support flange shaft with thrust piece 2050.
- Install circlip onto flange shaft
Prying off oil seal.
Preparing oil seal for installation
A - Shim 016311391A (1.4 mm thick)
B - Oil seal
- Pack space between sealing lip and dust lip half full with sealing grease G052128A1.
- Place shim and oil seal on tool, as shown in illustration.
Installation position: open side of oil seal points toward Torsen housing
Drive in seal onto stop.
- Remove shim.
Pressing out ball bearing for flange shaft
- Before pressing out ball bearing, remove circlip and sleeve.
Pressing in ball bearing for flange shaft
- Insert sleeve.
- Install circlip for ball bearing and sleeve
Installation position of circlips - A - and - B -.
A - Circlip for flange shaft
B - Circlip for ball bearing and sleeve