Differential, Disassembling and Assembling
Differential, disassembling and assembling, 02J, 5 Spd. M/T
Special tools and equipment:
- V.A.G 1582 Puller
- V.A.G 1582/3 Grip
- VW 412 Press tool
- 40-105 Thrust plate
- VW 401 Press plate
- VW 402 Press plate
Special tools and equipment:
- VW 408 A Press tool
- VW 473 Thrust piece
- 30-205 Thrust plate
- 3144 Sleeve
- 2007 Thrust pad
Note:
- Heat tapered roller bearing inner race to 100°C before installing.
- Always replace both tapered roller bearings together as a set.
- Adjust differential if tapered roller bearings, differential housing, transmission housing or clutch housing are being replaced.
1. Transmission housing
2. Bolt
3. Differential cage
^ Bolt to final drive gear
4. Final drive gear wheel
^ Riveted in production
^ Is paired with output shaft, only replace as a set
^ Pressing off go to Fig. 9
^ Installation position go to Fig. 10
^ Heat to 100°C before installing
^ Install to differential housing go to Fig. 11
^ Bolted go to Fig. 12
5. Backing plate
6. Nut, 70 Nm
7. Shim
^ For differential
^ Determining thickness
8. Tapered roller bearing outer race
^ Pulling out go to Fig. 5
^ Pressing in go to Fig. 6
9. Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
10. Differential housing
^ With riveted final drive gear
^ When replacing final drive gear drill out rivet heads go to Fig. 8
^ Attaching final drive gear with bolts go to Fig. 12
11. Speedometer drive wheel
^ Install onto differential housing as far as stop before pressing on inner race
12. Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
13. Tapered roller bearing outer race
^ Pressing out go to Fig. 1
^ Pressing in go to Fig. 2
14. Clutch housing
15. Sleeve
^ Installed together with springs behind flange shafts
^ To accept oil seal (item 16)
^ Removing and installing
16. Oil seal
^ Replacing with transmission installed
17. One piece oil seal and sleeve
^ If seal is damaged, replace oil seal and sleeve together
18. Cone head bolt, 25 Nm
^ Bolt into threaded piece (item 26)
19. Flange shaft
20. Spring for flange shaft
^ Installed behind flange shafts
21. Thrust washer
^ Installation position: Shoulder toward spring, tongue to tapered ring
^ Installation position with changed thrust washer go to Fig. 15
22. Tapered ring
^ With grooves to secure thrust washer
^ Installation position: Taper toward differential housing
23. Securing clip
^ Holds tapered ring, thrust washer and spring in position when drive flange is removed
24. One-piece thrust washer
^ Coat with transmission oil when installing
25. Sun gear
^ Installing go to Fig. 14
26. Threaded piece
^ Installing go to Fig. 14
27. Differential pinion shaft
^ Knock out with drift
^ Installing go to Fig. 14
28. Spring pin
^ For securing planet pinion axis shaft
^ Removing and installing go to Fig. 13
29. Differential pinion gear
^ Installing go to Fig. 14
30. Differential side gear
^ Installing go to Fig. 14
Fig. 1 Pressing tapered roller bearing outer race out of clutch housing
- For transmissions with springs behind flange shafts, first remove mounting sleeve for flange shaft seal.
Fig. 2 Pressing tapered roller bearing outer race into clutch housing
No shim is installed in the clutch housing end.
Fig. 3 Pulling off tapered roller bearing inner race
- Before installing extractor position press piece 40-105 on differential housing.
Note: Both 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 transmission housing and clutch housing are pressed on with the same press 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 21/7
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 from countersink side and knock-out with drift.
Note: Clean differential before and after drilling, 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 wheel
- The circular groove -A- faces toward bolt-on side of differential.
Fig. 11 Heating final drive gear wheel to approximately 100°C 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 according to 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.
- Knock-out spring pin with chisel, inserting chisel into circumferential groove.
Installing
- Knock fully into differential housing.
Fig. 14 Installing differential side gears and pinion gears
- Lubricate one piece thrust washer with transmission oil and install.
- Install both side gears and secure (e.g. with flange shaft).
- Insert pinion gears (180° apart) and pivot into position.
- Push pinion shaft (arrow -A-) in until first pinion gear.
- Position threaded pieces (arrow -B-) in side gears. Installation position: step faces side gear
- Drive pinion shaft into final position and secure with spring pin.
Fig. 15 Changed thrust washer for tapered ring -1-.
- Installation position:
- When the pads -A- are not present, the shoulder (arrow) points to spring -B-.