Differential, Disassembling and Assembling
Differential, disassembling and assembling, 012/01W, 5 SPD. M/T
Special tools, testers and auxiliary items required:
^ Thrust Plate VW 401
^ Thrust Plate VW 402
^ Punch VW 407
^ Punch VW 408 A
^ Thrust pad VW 447 H
^ Thrust pad VW 447 i
Special tools, testers and auxiliary items required:
^ Thrust Pad VW 472/1
^ Thrust Plate 2050
^ Drift 3138
^ Press Support-RI Wheel Brgs. 3144
^ Tube 3296
^ Torque Wrench 40-200 Nm V.A.G. 1332
Special tools, testers and auxiliary items required:
^ Press Appliance VW 459
^ 1 - Internal extractor Kukko 21/7
^ 3 - Extractor Kukko 204/2
^ 4 - Support Kukko 22/2
^ Two arm puller Kukko 44-2
Note:
^ As of 05.03 the beating seat for left tapered roller beating on differential housing are provided with larger radius at inner stop. Inner race of left tapered roller beating was also modified accordingly. Old version of tapered roller beating cannot be installed with new differential housings.
^ Replace both tapered roller beatings together.
^ Adjustments are required when replacing components marked with 1).
1. Transmission housing 1)
^ Made out of aluminum, may only be installed with transmission cover made out of aluminum
^ Made out of magnesium, may only be installed with transmission cover made out of magnesium
2. Adjustment shim "S2"
^ Note thickness
3. Outer race for right tapered roller bearing
^ Pulling out
^ Pressing in
4. Inner race for right tapered roller bearing
^ Pull off
^ Pressing on
5. Ring gear
^ Is matched to drive pinion (gear set)
^ Press off of housing using drift
^ Install on differential housing
6. Differential housing 1)
^ Reinforcement measures as of 08.98 (phased in introduction)
^ Modified left bearing seat as of transmission manufacture date 23 06 3
7. Bolt, 60 Nm and 45° (1/8 additional turn)
^ Always replace
^ Lightly tighten bolts then tighten diagonally to correct torque.
8. Inner race for left tapered roller bearing 1)
^ Reinforcement measures as of 08.98 (phased in introduction)
^ Tapered roller bearing modified as of transmission manufacture date 23 06 3 and
^ Pull off
^ Pressing on
9. Drive gear for speedometer
^ Carefully install onto differential without canting. Do not use force, drive gear can break
10. Outer race for left tapered roller bearing 1)
^ Reinforcement measures as of transmission manufacture date 17 08 8 (phased in introduction)
^ Tapered roller bearing modified as of transmission manufacture date 23 06 3
^ Driving out
^ Press in up to transmission manufacture date 16 08 8
^ Press in as of transmission manufacture date 17 08 8
11. Adjustment shim "S1"
^ Note thickness
12. Cover for final drive 1)
^ Made out of aluminum, may only be installed with transmission housing made out of aluminum
^ Made out of magnesium, may only be installed with transmission housing made out of magnesium
^ Reinforcement measures as of transmission manufacture date 17 08 8 (phased in introduction)
^ Coat sealing surfaces with a thin layer of sealant AMV 188 001 02
13. Large differential bevel gear
^ Installing
14. Shaft for differential bevel gears
^ Drive out using drift after removing roll pin
15. roll pin
^ For securing shaft for differential bevel gears
^ Version with annular groove: Removing and installing
^ Version without annular groove: Drive out using drift
16. Small differential bevel gear
^ Installing
17. Thrust washer connection
^ Lubricate with transmission fluid before installing
Pulling outer race/tapered roller bearing out of transmission housing
A - Support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
^ Check adjustment shims for damage after removing.
Pressing outer race/tapered roller bearing into transmission housing
^ Insert Thrust Pad VW 472/1 together with cone in outer race.
^ Support transmission housing directly beneath bearing mount using press appliance VW 459/2.
Pulling off right tapered roller bearing inner race
A - Two arm puller, e.g. Kukko 20/10 or Kukko 44/2
Note:
^ The differential housing has a notch under the beating seat to install puller - A
Pressing on right tapered roller bearing inner race
CAUTION: Wear protective gloves!
^ Heat inner race to approximately 100°C, install and press on.
Pulling off left tapered roller bearing inner race
A - Two arm puller, e.g. Kukko 204/2
Note:
^ The differential housing has a notch under the beating seat to install puller - A -.
Installing left tapered roller bearing inner race
CAUTION: Wear protective gloves!
^ Heat inner race to approximately 100°C, install and press on.
Driving out outer race of left tapered roller bearing from cover
^ Turn webs - A - and - B - out until they sit on outer race within recess in transmission.
^ Check adjustment shims for damage after removing.
Driving in outer race of left tapered roller bearing into cover in transmissions without reinforcement measures up to transmission manufacture date 16 08 8
^ Insert Thrust Pad VW 472/1 together with cone in outer race.
Driving in outer race of left tapered roller bearing into cover in transmissions with reinforcement measures as of transmission manufacture date 17 08 8
^ Outer race for left tapered roller bearing must be pressed into cover using Thrust Plate 2050.
^ Insert Thrust Plate 2050 together with cone in outer race.
Driving out ring gear from housing
Heat ring gear to approximately 100°C and install
CAUTION: Wear protective gloves!
^ When installing ring gear, guide with centering pins - A - (self-made).
^ Before installing mounting bolts let it cool off. Tighten to specified torque.
Installing small differential bevel gears
^ Lubricate one-piece thrust washer with transmission fluid before installing.
^ Install large differential bevel gears.
^ Install small differential bevel gears at 180° from their final position and rotate into place - arrow -.
^ Drive in differential bevel gear shaft to final position and secure.
Removing and installing roll pin
Removing
^ Remove roll pin with annular groove using diagonal-cutting pliers.
^ Remove roll pin without annular groove using punch.
Installing
^ Install roll pin to stop.