Differential, Disassembling and Assembling
Differential, disassembling and assembling - 6 Spd. Manual Transmission 02X All Wheel Drive
Special tools, testers and auxiliary items required
^ Thrust plate VW401
^ Thrust plate VW402
^ Punch VW407
^ Punch VW408A
^ Thrust pad VW447H
^ Thrust pad VW 447i
Special tools, testers and auxiliary items required
^ Needle bearing drift VW 295
^ Thrust ring VW 470
^ Sleeve 30 - 14
^ Thrust plate 2050
^ Thrust pad 3005
^ Tube 3296
Special tools, testers and auxiliary items required
^ Torque wrench V.A.G 1332
^ Taper roller bearing puller V.A.G 1582
^ Adapter V.A.G 1582/1
^ Adapter V.A.G 1582/8
^ - 1 - Internal puller Kukko 21/8
^ - 4 - Counter-support Kukko 22/2
Removing and installing differential.
Note:
^ Always replace both tapered roller bearings together.
^ Adjustment work is required when replacing the parts marked with 1). Table of adjustments
1 - Transmission housing 1)
2 - Shim "S2"
^ Note thickness
^ Table of adjustments
3 - Outer race for tapered roller bearing (right-side)1)
^ Pulling out
^ Driving in
4 - Inner race for tapered roller bearing (right-side)1)
^ Pulling off
^ Pressing on
5 - Ring gear1)
^ Is paired with pinion shaft (final drive set)
^ Select correct version according to transmission code letters
^ Drive off housing using a punch installing onto differential cage
6 - Differential cage1)
7 - Bolt, 30 Nm plus an additional 90 degrees 1/4 turn
^ Replace
^ Lightly tighten bolts then tighten in diagonal sequence to correct torque
8 - Inner race for tapered roller bearing (left-side)1)
^ Pulling off
^ Pressing on
9 - Outer race for tapered roller bearing (left-side)1)
^ Pulling out
^ Pressing in
10 - Shim "S1"
^ Note thickness
^ Table of adjustments
11 - Cover for final drive 1)
^ With O-ring
12 - One-piece thrust washer
^ Lubricate with gear oil before installing
13 - Sun wheel
^ Installing
14 - Differential pinion pin
^ Drive out with drift after removing spring pin
15 - Spring pin
^ For securing differential pinion pin
^ Drive out from differential cage with drift
^ Pressing in value: 1.5 mm above differential cage
16 - Planetary pinion
^ Installing
Pulling tapered roller bearing outer race (right-side) out of transmission housing
A - Counter-support, e.g. Kukko 22/2
B - Internal puller 56 to 70 mm, e.g. Kukko 21/8
- After removing, check shims for damage.
Driving outer race for tapered roller bearing (right-side) into transmission housing
Pulling off inner race for tapered roller bearing (right-side)
- Before setting up the puller, place thrust pad VW 447 H on differential cage.
Pressing on tapered roller bearing inner race (left and right)
Note:
^ Use the same tools for pressing on tapered roller bearing inner race on left side and right side.
CAUTION!
Wear protective gloves.
- Heat inner race to approx. 100 degrees C, install in position and press home.
Pulling off inner race for tapered roller bearing (left-side)
- Before setting up the puller, place thrust pad VW 447 H on differential cage.
Pulling tapered roller bearing outer race (left-side) out of cover for final drive
A - Counter-support, e.g. Kukko 22/2
B - Internal puller 56 to 70 mm, e.g. Kukko 21/8
- After removing, check shims for damage.
Pressing tapered roller bearing outer race (left-side) into cover for final drive.
Driving ring gear off cage
Heating ring gear to approx. 100 degrees C and installing
- When installing ring gear, use centralizing pins - A - (shop-made tool) to locate.
CAUTION!
Wear protective gloves.
- Allow to cool slightly before screwing in new securing bolts. Then tighten to specified torque.
Installing differential bevel gears
- Lubricate one-piece thrust washer with gear oil and install.
- Insert sun wheels.
- Insert planet pinions offset 180 degrees and rotate into position - arrow -.
- Drive differential pinion pin into final position and secure.