Differential, Removing and Installing

Differential, removing and installing - 6 Spd. Manual Transmission 02X All Wheel Drive





Special tools, testers and auxiliary items required

^ Slide hammer-complete set VW771
^ Socket (27 mm) 3257
^ Torque wrench V.A.G 1331
^ - 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/hollow shaft or 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, - Item 4 -.
^ 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 ring gear1)

^ Disassembling and assembling

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 cant 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 faulty.





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 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.

- Knock 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 new flange shaft oil seal using fitting drift 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.