Dissassembly/Assembly

- Drilling rivet heads for gear removal
^ Drill out rivet heads from countersunk side using 12 mm (0.472 in.) drill, then drive out rivets

- Pressing off final drive gear

- Installing final drive gear
^ Heat gear to approx. 100°C (212°F) before installation
^ Use bolts (A) from repair kit to guide final drive gear on during installation

- Attaching final drive gear to differential housing
^ Special bolts, washers and nuts - part no. 171 498088 A (repair kit)
^ Tighten to: 65 Nm (48 ft lb)

2 Special rivet
- Secures shaft for differential gears
- When repairing differential, secure shaft with circlips after removing rivet

- Sawing off special rivets
^ Saw special rivets off evenly, drive shaft out using drift and swing pinion gears out of housing

CAUTION:
- Clean the differential before and after sawing or drilling.
- Protect the tapered roller bearings from filings.

3 Tapered roller bearing inner race, opposite final drive gear

- Removing tapered roller bearing inner race
^ Place 3002 pressure piece on differential housing before assembling extraction tool

NOTE:
- The procedure for removing the inner races of tapered roller bearings of differential housing is the same on both sides.
- The tapered roller bearings are destroyed during removal.

- Pressing on inner race of tapered roller bearing for differential housing
^ Preheat inner race to approx. 100°C (212°F) and install
^ The recessed side of the VW455 thrust tube faces the tapered roller bearing

4 Tapered roller bearing outer race

- Removing tapered roller bearing outer race from clutch housing

- Installing tapered roller bearing outer race into clutch housing

5 Shim S2
- Always 1 mm thick
6 Securing set
- For attaching final drive gear to differential housing when servicing the final drive gear
- Original production parts (rivets item 27) are not used
- Torque 65 Nm (48 ft lb)
7 Clutch housing
8 Sleeve
- Remove/Install - Bell Housing
9 Oil seal
- Remove/Install - Seals and Gaskets
10 Drive flange output shaft
- Remove circlip (23) before removing
- Turn lightly during removal
- Press in carefully during installation
- Threaded socket is opposite differential bearings
- Do not damage thrust washer
11 Tapered roller bearing inner race, final drive gear side
- First remove drive flange output shafts (10)
- Adjust differential after replacement - Ring Gear

- Pressing on inner race of tapered roller bearing for differential housing
^ Preheat inner race to approx. 100°C (212°F) and install

NOTE: When using the VW455 thrust tube, the recessed side faces the tapered roller bearing.

12 Tapered roller bearing outer race

- Removing tapered roller bearing outer race out of transmission housing

- Installing tapered roller bearing outer race into transmission housing

13 Shim S1
- Determining size - Ring Gear
14 Transmission housing
- Servicing - Transmission Housing
15 Circlip
- Always replace
- Must seat securely in groove
16 Dished washer
17 Drive flange
- Removing and installing - Seals and Gaskets
18 Spring
19 Thrust washer
20 Tapered ring
21 Differential housing
- Adjust differential after replacement
22 One-piece thrust washer
- Lubricate with gear oil before installation
23 Circlip
- Secures drive flange output shaft (10)
24 Shaft for differential gears

- Sawing off special rivets for removal of differential pinion gears
^ Saw special rivets off evenly, drive shaft out using drift and swing pinion gears out of housing

CAUTION:
- Clean the differential before and after sawing.
- Protect the tapered roller bearings from filings.

25 Circlip
26 Differential gears
- Removing- Sawing off rivets: reference (24)

- Installing differential pinion gears
^ Lubricate one-piece thrust washer with gear oil and install
^ Insert planetary pinions, drive in shaft and secure with new circlips

CAUTION: If the shaft is not equipped with grooves for circlips, install new shafts. Only shafts with grooves are supplied as replacement parts.

^ Insert large differential pinion gears with 180° offset and swing into housing (arrow)

27 Rivet
- For attaching final drive gear to differential housing
- For production only
- For repairs, use securing set (6)
- Removal - drilling out: reference (1)
28 Cover
- Destroyed by removal