Transmission Without Oil Pump

Differential, disassembling and assembling (transmission without Oil pump)





Special tools and equipment
^ VW 295 Drift
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 412 Press tool
^ VW 459 Installation and removal tool
^ VW 470 Thrust pieces for drive pinion bearing





Special tools and equipment
^ 30-205 Thrust plate
^ 30-505 Mandrel
^ 40-21 Press tool
^ 40-105 Thrust plate
^ 3062 Press disk
^ 3138 Driver






Special tools and equipment
^ VAG 1582 Tapered roller bearing puller
^ VAG 1582/3 Grip
^ VAG 1582/6 Grip

Note: Components marked with [1] indicate adjustment work is required if these components are replaced; Refer to Differential Assembly; Adjustment overview.





1. Transmission housing[1]
2. Shim S2
^ Note thickness
^ Refer to Adjustment overview
3. Small tapered roller bearing outer race[1]
^ Driving out
^ Driving in; Refer to Fig. 10
4. Small tapered roller bearing inner race[1]
^ Pulling off
^ Pressing on
5. Ring gear[1]
^ Is mated to pinion shaft (pinion set)
^ Determine according to transmission code letters using Parts Supplier
^ Drive off with a drift
^ Install on differential cage
6. Differential cage [1]
7. Hex bolt, 60 Nm then turn 45° further
^ Always replace
^ Always use genuine spare parts
8. Large tapered roller bearing inner race[1]
^ Pulling off
^ Pressing on
9. Speedometer drive wheel
10. Large tapered roller bearing outer race[1]
^ Knocking out; Refer to Fig. 11
^ Driving in; Refer to Fig. 12
11. Shim S1
^ Note thickness
^ Refer to Differential Assembly,Adjustment overview
12. Cover for final drive[1]
^ With O-ring
^ Replace O-ring
^ Oil O-ring before installing
13. Shim
^ Recalculate thickness
14. Large differential bevel gear
^ Installing
^ Adjusting
15. Threaded piece
16. Thrust washer
^ Check for cracks and chips
17. Small differential bevel gear
^ Installing - Fig.7
^ Adjusting - Fig.8
18. Differential bevel gear axis shaft
^ After removing spring pin, drive out with drift
^ Before driving in, adjust thrust washers
19. Spring pin
^ Always replace
^ Drive in flush





Fig. 1 Pulling off small tapered roller bearing inner race
- Before mounting extractor position press piece 40-105 on differential housing.





Fig. 2 Pulling off large tapered roller bearing inner race
- Remove speedometer drive wheel.
- Before mounting extractor position press piece 40-105 on differential housing.





Fig. 3 Pressing on small tapered roller bearing inner race
- Press tapered roller bearing inner race onto stop on differential cage.





Fig. 4 Pressing on large tapered roller bearing inner race
- Press tapered roller bearing inner race onto stop on differential cage.
- Install speedometer drive wheel.





Fig. 5 Driving ring gear off housing





Fig. 6 Heating ring gear to approximately 100°C and installing

- Guide ring gear with centralizing pins -A- (local manufacture) when installing. Observe work safety regulations.

WARNING!: Wear protective gloves!

- Let securing bolt cool slightly before screwing in. Then tighten to torque.





Fig. 7 Installing large and small differential bevel gears

- Install small bevel gear thrust washers with a little grease.
- Install large bevel gears with selected shims - Fig.8.
- Insert small bevel gears turned through 180° and pivot into position (arrow).
- Insert threaded pieces.
Installed position: step facing large bevel gear
- Position thrust washers so they line up with holes.
- Drive differential bevel gear axis shaft into final position and secure.





Fig. 8 Adjusting large and small bevel gears

- Insert large bevel gears with thinnest shims (0.5 mm).
- Insert small bevel gears with thrust washers and press in shaft.

Note: Do not interchange position of large bevel gears and thrust washers after this.

- Press bevel gears outward and check large bevel gear play by hand (arrows).
- Adjust play by inserting an appropriate shim.
Specification: max. 0.10 mm





Note:
^ The adjustment is also correct when no more play can be felt but the shafts and gears can just still be turned (arrow).
^ Determine shims according to Parts Supplier.





Available shims





Fig. 9 Driving small tapered roller bearing outer race out of transmission housing





Fig. 10 Pressing small tapered roller bearing outer race into transmission housing





Fig. 11 Driving large tapered roller bearing outer race out of cover
Use appropriate support, e g. VW 470 with notch facing cover.





Fig. 12 Pressing large tapered roller bearing outer race into cover