Disassembling and Assembling

5 Speed Manual 02J

Differential, Disassembling and Assembling

Special tools






- VAG 1582 Bearing puller
- VAG 1582/3 Grip piece
- VW 412 Thrust disc
- 40-105 Thrust piece
- VW 401 Thrust plate
- VW 402 Thrust plate






- VW 408 A Punch
- VW 473 Thrust piece
- 30-205 Thrust pad
- 3144 Press support
- 2007 Thrust pad

Note:

- Heat tapered roller bearing inner race to 100°C (212°F) before installing.
- Always replace both tapered roller bearings together as a set.
- If differential housing, transmission housing or clutch housing tapered roller bearings are replaced, adjust differential.






1 Transmission housing
2 Bolt
3 Differential cage
- Bolt to final drive gear
4 Final drive gear
- Riveted in production
- Is paired with output shaft, only replace as a set
- Pressing off refer to Fig. 9
- Installation position refer to Fig. 10
- Heat to 100°C (212°F) before installing
- Mount to differential housing Fig. 11
- Bolting refer to Fig. 12
5 Plate
6 Nut
- 70 Nm (52 ft. lbs.)
7 Shim
- For differential
- Determining thickness
8 Tapered roller bearing outer race
- Pulling out refer to Fig. 5
- Pressing in refer to Fig. 6
9 Tapered roller bearing inner race
- Pulling off refer to Fig. 3
- Pressing on refer to Fig. 4
10 Differential housing
- With riveted final drive gear
- When replacing final drive gear drill out rivet heads refer to Fig. 8
- Attaching final drive gear with bolts refer to Fig. 12
- Both sides are chamfered to accept tapered rings (item 21) in transmissions with springs behind flange shafts refer to Fig. 7
11 Speedometer drive gear
- Install on differential housing before pressing on inner race
12 Tapered roller bearing inner race
- Pulling off refer to Fig. 3
- Pressing on refer to Fig. 4
13 Tapered roller bearing outer race
- Driving out refer to Fig. 1
- Pressing in refer to Fig. 2
14 Clutch housing
15 Sleeve
- To accept oil seal (item 16)
16 Oil seal
17 Cone-head bolt
- 25 Nm (18 ft. lbs.)
- Bolt into threaded piece (item 25)
18 Flange shaft
19 Spring for flange shaft
- Installed behind flange shafts
20 Thrust washer
- Installation position: Shoulder toward spring, tongue to tapered ring
21 Tapered ring
- With grooves to secure thrust washer
- Installation position: -Taper toward differential housing
22 Circlip
- Ensures tapered ring, thrust washer and spring are held in position when flange shaft is removed
23 One-piece thrust washer
- Coat with gear oil when installing
24 Differential side gear
- Installing see Fig. 14
25 Threaded piece
- Installing refer to Fig. 14
26 Differential pinion shaft
- Drive out with drift
- Installing refer to Fig. 14
27 Spring pin
- Removing and installing refer to Fig. 13
28 Differential pinion gear
- Installing refer to Fig. 14
29 Differential side gear
- Installing refer to Fig. 14

Fig. 1 Driving tapered roller bearing outer race out of clutch housing






Fig. 2 Pressing tapered roller bearing outer race into clutch housing






Note:
No shim is installed in the clutch housing end.

Fig. 3 Pulling off tapered roller bearing inner race





- Position thrust piece 40-105 on differential housing.
- Install puller.

Note:
Bot tapered roller bearing inner races are pulled off the differential housing in the same way

Fig. 4 Pressing on tapered roller bearing inner race






Note:
The tapered roller bearing inner races for the transmission and clutch housings are pressed on with the same tools.

Fig. 5 Pulling tapered roller bearing outer race out of transmission housing





A Counter support, e.g. Kukko 22/2
B Internal puller, 46 - 58 mm, e.g. Kukko 2117

Fig. 6 Pressing tapered roller bearing outer race into transmission housing





- Install shim under outer race.
- Support transmission housing with sleeve 3144 directly below bearing mounting.

Fig.7 Both sides of differential housing are chamfered (arrow) to accept tapered rings/springs






Fig. 8 Drilling out rivet heads





- Drill out rivet heads with 12 mm drill on countersunk side and drive-out with drift.

Note:
Clean differential before and after drilling, and protect tapered roller bearing from drillings.

Fig. 9 Pressing off final drive gear





- Place thrust piece 40-105 on differential housing.

Fig. 10 Installation position of final drive gear





The circular groove -A- faces toward bolt-on side of differential.

Fig. 11 Heating final drive gear to approx. 100°C (212°F) and installing





Use bolts -A- from repair kit to guide final drive gear into position during installation.

Fig. 12 Bolting final drive gear and differential housing together





Use special bolts with plates and nuts as specified in the parts catalog.

Fig. 13 Removing and installing differential pinion shaft spring pin






Removing
- Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.
- Insert chisel into circumferential groove and drive-spring pin out.

Installing
- Drive spring pin fully into differential housing.

Fig. 14 Installing differential side gears and pinion gears





- Lubricate one piece thrust washer with gear oil and install.
- Install both side gears and secure (e.g. with flange shaft).
- Turn pinion gears through 180° and pivot into position.
- Push pinion shaft (arrow -A-) in until first pinion gear is contacted.
- Position threaded piece (arrow-B-) in side gears (installation position: step toward side gear)
- Drive pinion shaft into final position and secure with spring pin.