Differential, Removing and Installing

Differential, removing and installing - 6 Spd. M/T 01X Front Wheel Drive





Special tools, testers and auxiliary items required

^ Slide hammer-complete set VW771
^ Socket (27 mm) 3257
^ Torque wrench V.A.G1331
^ - 1 - Internal puller Kukko 21/5

Note:
^ Removing and installing is possible with the transmission installed.
^ The differential can be removed and installed without removing the selector mechanism, input shaft, pinion shaft and bearing housing. These components must be removed if the differential needs to be adjusted.
^ Inspect polygon bearings for visible 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 not necessarily 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 the differential sun wheel on flange shafts with 30 mm spline diameter, - Item4 -.
^ Adjustment work is required when replacing the parts marked with 1).





1 - Transmission housing 1)
2 - Oil seal

^ Removing (left-side)
^ Installing (left-side)
^ Removing (right-side)
^ Installing (right-side)

3 - Circlip

^ Replace
^ Removing and installing

4 - Spacer ring

^ Is only installed on flange shafts with a spline diameter of 30 mm
^ Remove with Internal puller 30 to 37 mm, e.g. Kukko 21/5
^ Installing

5 - Flange shaft

^ Removing (left-side)
^ Removing (right-side)
^ Drive in with drift VW295.
^ Flange shaft assembly

6 - Differential with crown wheel 1)

7 - O-ring

^ Always replace
^ Lubricate with gear oil

8 - Cover for final drive 1)
9 - TORX bolt, 20 Nm plus an additional 90 degrees 1/4 turn





Removing flange shaft (left-side)

- Remove flange shaft (left-side); by securing puller T10037 to cover for final drive - arrow -.





Remove right flange shaft

- Remove flange shaft (right-side); by securing puller T10037 to transmission housing - arrow -.





Removing and installing circlip

- Clamp flange shaft in vise, using jaw protectors. Use new circlip - A - to press old circlip out of groove in flange shaft.





Installing spacer ring

- Drive new spacer ring in onto stop; do not tilt ring when doing this.





Flange shaft assembly

1. Flange shaft
2. Needle bearing (polygon bearing)
3. Spacer ring
4. Spacer ring - installed on shafts with 30mm spline diameter
5. Circlip

Note:
^ The needle bearing (polygon bearing) does not turn easily when the flange shaft is removed. This does not indicate that the bearing is defective.





Removing flange shaft oil seal (left-side)

- Pry out flange shaft oil seal using an assembly lever.





Installing flange shaft oil seal (left-side)

- Lightly oil outer circumference of new seal.
- Drive in new flange shaft oil seal using driver 2062; keep seal straight when installing.

^ Insertion depth: 5.50 ±0.15 mm below top of cover.
^ Pack space between sealing lip and dust lip half-full with sealing grease G052128A1.

- Drive flange shaft in with needle bearing drift VW295.





Removing flange shaft oil seal (right-side)
- Pry out flange shaft oil seal - arrow - using an assembly lever.





Installing flange shaft oil seal (right-side)

- Lightly oil outer circumference of new seal.
- Drive in new flange shaft oil seal using driver 2062; keep seal straight when installing.

^ Insertion depth: 5.50 ±0.15 mm below top of cover.
^ Pack space between sealing lip and dust lip half-full with sealing grease G052128A1.