Differential, Removing and Installing

Differential, removing and installing

Required special tools and equipment:





^ VW 681 Oil seal extractor
^ 3155 Ring nut wrench
^ 3301 Spindle with nut from assembly tool
^ 3319 Thrust piece
^ V.A.G 1332 Torque wrench or similar
^ Kukko 18/0 Puller
^ 2 Bolts M8 x 35 mm
^ Washers 8 mm

Note:
^ If you plan to use taper roller bearings again, mark adjusting ring refer to Fig. 2
^ The drive pinion does not need to be removed for removing and installing the differential.





1 Transmission housing
2 Speedometer drive
^ With marking for oil level indication refer to Fig. 4
3 Output shaft/drive flange
^ Install thread facing drive flange
^ Remove before taking out differential
^ First adjust differential before installing
4 O-ring
^ Always replace
5 Adjusting ring
^ Removing refer to Fig. 3
^ If you plan to use bearings again, mark installation position and position on marking again when installing refer to Fig. 2
^ If you install new bearings, follow adjusting instructions
6 Oil seal for drive flange
^ Before installing, pack space between sealing lips with multi-purpose grease
^ Oil seal can be replaced with transmission installed
^ Remove with VW 681
^ Driving in refer to Fig. 1
7 Taper ring
^ Shoulder faces thrust washer
8 Thrust washer
^ Place over compression spring
9 Compression spring
10 Drive flange
^ Insert with taper ring, thrust washer and compression spring
^ Remove before taking out inner circlip on bevel gear
^ Removing and installing refer to Fig. 8
11 Dished washer
12 Circlip
^ Removing and installing refer to Fig. 7
13 Cover
14 Locking element
15 Screw, 12 Nm (9 ft. lbs.)
16 Cover
17 Circlip
^ Removing and installing refer to Fig. 7
18 Dished washer
19 Drive flange
^ Insert with taper ring, thrust washer and compression spring
^ Remove before taking out inner circlip on bevel gear
^ Removing and installing refer to Fig. 8
20 Compression spring
21 Thrust washer
^ Place over compression spring
22 Taper ring
^ Shoulder faces thrust washer
23 Oil seal for drive flange
^ Before installing, pack space between sealing lips with multi-purpose grease
^ Oil seal can be replaced with transmission installed Remove with VW 681 Driving in refer to Fig. 1
24 Bearing body, 150 Nm
^ When installing new bearing, follow adjusting instructions
^ Remove with 3155
^ Installing refer to Fig. 5
25 O-ring Always replace
26 Output shaft/drive flange
^ Install thread facing drive flange
^ Before removing, take out differential
^ First adjust differential before installing
27 Differential
^ Disassembling and assembling
^ Before removing differential, take out bearing body, adjusting ring and output shafts
28 Screw, 12 Nm (9 ft. lbs.)
29 Locking element

Note:
After adjusting taper roller bearings, secure bearing body and adjusting ring.

30 Circlip
^ First remove drive flange before removing circlip
^ Removing and installing refer to Fig, 6
31 Circlip
^ First remove drive flange before removing circlip
^ Removing and installing refer to Fig. 6
32 Seal
^ Always replace
33 Cover
^ For differential
34 Screw, 28 Nm (21 ft. lbs.)
^ Insert with locking compound AMV 185 101 A1





Fig. 1 Drive in flange oil seal to stop





Fig. 2 Adjusting ring, marking
^ If you plan to re-install used bearings, mark installation position -arrow- and align with markings when installing.





Fig. 3 Adjusting ring, removing





Fig. 4 Speedometer drive
^ With transmission installed, check gear oil in final drive.





Fig. 5 Insert differential and screw in bearing body to stop and tighten to 150 Nm (111 ft. lbs.)





Fig. 6 Circlip -arrow-, installing
^ Remove circlip with two screwdrivers.





Fig.7 Circlip for axle flange, removing and installing
^ Remove spindle from bridge -A- of puller Kukko 18-0.
^ Replace spindle with spindle and nut of assembly tool 3301.
^ Install puller Kukko 18-0 to flange, using two 8x35 mm bolts and 8 mm washers.
^ Remove circlip -arrow- for axle flange.





Fig 8 Drive flange, removing and installing

Removing:
^ Install puller Kukko 18-0 to flange, using two 8 x 35 mm bolts and 8 mm washers.
^ Pull off drive flange.

Installing:
^ Attach puller 18-0 to axle flange.
^ Replace spindle -B- of Kukko 18-0 with spindle and nut of assembly tool 3301 refer to Fig. 7.
^ Install drive flange with 3109.

Note:
Drive flange can also be pulled in with VW 391.