Differential, Disassembling and Assembling

Differential, Disassembling and assembling

Required special tools and equipment:











^ VW 402 Press plate
^ VW 408 A Press tool
^ VW 411 Press tool
^ 30-205 Thrust plate
^ 40-21 Press tool
^ V.A.G 1582 Taper roller bearing puller
^ V.A.G 1582/3 Clamping ring
^ 30-555 Thrust piece

Note:
^ Heat taper roller bearing inner race to 100 °C (212°F) before pressing on.
^ Heat adjusting ring for taper roller bearing to 100 °C (212°F) before pressing in taper roller bearing outer race.





1 Differential housing with riveted gear for final drive
^ Final drive gear is riveted to differential housing and then machined
^ If differential or final drive gear is damaged, replace differential housing together with riveted final drive gear
^ Number of teeth on final drive gear
2 Output shaft/drive flange Removing and installing
3 Taper roller bearing inner race
^ Pulling off refer to Fig. 1
^ Pressing on refer to Fig. 2
4 Taper roller bearing outer race
^ Remove and install only when adjusting ring is heated
^ Drive out with drift
^ Pressing in refer to Fig. 4
5 Bearing body for taper roller bearing
^ Removing and installing
6 O-ring
^ Always replace
7 O-ring
^ Always replace
8 Adjusting ring for taper roller bearing
^ Removing and installing
9 Output shaft/drive flange
^ Removing and installing
10 Taper roller bearing outer race
^ Remove and install only when adjusting ring is heated
^ Drive out with drift
^ Pressing in refer to Fig. 4
11 Taper roller bearing inner race
^ Pulling off refer to Fig. 1
^ Pressing on refer to Fig. 2
12 Driver bushing
^ Drive off together with speedometer drive gear -item 13-
^ Drive on with drift
13 Speedometer drive gear
^ Drive out with a drift
^ Install together with driver bushing -item 12-
14 One-piece thrust washer
^ Place into differential housing before inserting bevel gears
15 Small bevel gears
^ Inserting refer to Fig. 3
16 Large bevel gears
^ Inserting refer to Fig. 3
17 Circlip

CAUTION!
Do not remove circlip before pulling off drive flange as the compression spring is pre-tensioned.

18 Shaft for bevel gears
^ Drive out with drift
^ When driving in, be careful not to damage one-piece thrust washer
19 Spring pin
^ To secure shaft for bevel gears
^ Removing and installing refer to Fig. 5





Fig. 1 Taper roller bearing inner race, removing
^ Place press piece 30-555 on differential housing.





Fig. 2 Taper roller bearing inner race, installing





Fig. 3 Differential bevel gears, installing
^ Insert one-piece thrust washer with gear oil.
^ Insert small bevel gears, drive in shaft and secure with spring pin.
^ Insert large bevel gears offset by 180° and move it in direction of arrow.





Fig. 4 taper roller bearing outer race, pressing in
^ With adjusting ring or bearing body heated, insert outer race and press in to stop.





Fig. 5 Planet wheel axle shaft spring pin, removing and installing
^ Length of spring pin 28.5 mm

Removing:
^ Pull out spring pin with side cutter.

Installing:
^ Drive in spring pin to stop.