Differential, Disassembling and Assembling
Differential, disassembling and assembling, 02M, 5 and 6 Spd. M/T
Special tools and equipment:
- VW 353 Transmission support
- VW 401 Thrust plate
- VW 402 Thrust plate
- VW 407 Press tool
- VW 408 A Press tool
- VW 412 Press tool
Special tools and equipment:
- 40-105 Thrust plate
- 3005 Press disk
- 3259 Tube
- 3296 Tube
- 3345 Tube
- V.A.G 1332 Torque wrench or equivalent
Special tools and equipment:
- V.A.G 1582 Tapered roller bearing puller
- V.A.G 1582/6 Grip
1 - Kukko 21/7 Internal puller
4 - Kukko 22/2 Counter support
Note:
- Heat tapered roller bearing inner race to 100°C before installing.
- Always replace both tapered roller bearings together as a set.
- If tapered roller bearings, differential housing, transmission housing or clutch housing are replaced, adjust differential.
1. Transmission housing
2. Bolt
3. Differential cage
^ Bolt to final drive gear Fig 10
^ Use Parts catalog to check correct application
4. Final drive gear
^ Riveted in production
^ Pressing off go to Fig. 8
^ Installed position: machined side faces bolting surface of differential housing
^ Heat to 100°C before installing
^ Fit to differential housing go to Fig. 9
^ Bolted go to Fig. 10
5. Backing plate
6. Nut, 40 Nm and 1/8 turn (45°) further
7. Clutch housing
8. Shim
^ For differential
^ Determining thickness
9. Tapered roller bearing outer race
^ Pulling out go to Fig. 5
^ Pressing in go to Fig. 6
10. Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
11. Differential housing
^ With riveted final drive gear
^ When replacing final drive gear drill out rivet heads go to Fig. 7
^ Attaching final drive gear with bolts go to Fig. 10
12. Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
13. Tapered roller bearing outer race
^ Pulling out go to Fig. 1
^ Pressing in go to Fig. 2
14. Shim
^ Always 0.65 mm thick
15. Oil seal
^ For right side flanged shaft
^ Left and right side diameters differ
^ Use Parts catalog to check correct application
^ Replacing with transmission installed
16. Counter-sunk head bolt, 25 Nm
^ Bolt into threaded piece (item -26-)
17. Left flanged shaft
^ Do not interchange, left and right side flange shafts differ
^ Use Parts catalog to check correct application
18. Spring for flanged shaft
^ Installed behind flanged shafts
19. Thrust washer
^ Installed position: shoulder toward spring, tongue to tapered ring
20. Tapered ring
^ With grooves to secure thrust washer
^ Installed position: Taper toward differential housing
21. Securing clip
^ Ensures that tapered ring, thrust washer and spring are held in position when flanged shaft is removed
22. Large differential bevel gear
^ Installing go to Fig. 12
^ Use Parts catalog to check correct application
23. Differential bevel gear shaft
^ Knock out with drift
^ Installing go to Fig. 12
^ Use Parts catalog to check correct application
24. Spring pin
^ For securing differential bevel gear shaft
^ Use Parts catalog to check correct application
^ Removing and installing go to Fig. 11
25. Small differential bevel gear
^ Installing go to Fig. 12
^ Use Parts catalog to check correct application
26. Threaded piece
^ Installing go to Fig. 12
27. One-piece thrust washer
^ Coat with transmission oil when installing
28. Left flanged shaft
^ Do not interchange, left and right flanged shafts differ
^ Use Parts catalog to check correct application
29. Oil seal
^ For left flanged shaft
^ Left and right side diameters differ.
^ Replacing with transmission installed
Fig. 1 Pulling tapered roller bearing outer race out of clutch housing
- A - Counter support, e.g. Kukko 22/2
- B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Note: After pulling out, check washer for damage and replace if necessary.
Fig. 2 Pressing tapered roller bearing outer race into clutch housing
- First insert washer.
Fig. 3 Pulling off tapered roller bearing inner race
- Before mounting 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 the 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 to 58 mm, e.g. Kukko 21/7
Fig. 6 Pressing tapered roller bearing outer race into transmission housing
- Support transmission housing with tube 3345 directly below bearing mounting.
Fig. 7 Drilling out rivet heads
- Drill out rivet heads with 12 mm drill from countersunk side and drive rivet out with drift.
Note: Clean differential before and after drilling; protect tapered roller bearing from metal particles.
Fig. 8 Pressing off final drive gear
- Place thrust piece 40-105 on differential housing.
Fig. 9 Heating final drive gear to approximately 100°C and installing
- Use bolts -A- from repair kit to guide final drive gear into position during installation.
Fig. 10 Bolting final drive gear -A- and differential housing -B- together
- Use special bolts -1- with backing plates -2- and nuts -3- according to parts catalog.
Fig. 11 Removing and installing differential bevel gear shaft spring pin
Removing
- Cover tapered roller bearing inner race 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 cage.
Fig. 12 Installing differential bevel gears
- Lubricate one piece thrust washer with transmission oil and install.
- Install both large differential bevel gears and secure (e.g. with flanged shaft).
- Insert small differential bevel gears (180° apart) and pivot into position.
- Push differential bevel gear shaft (arrow -A-) in up to first small bevel gear.
- Position threaded pieces (arrow -B-) in large bevel gears.
- Installed position: shoulder to bevel gear
- Drive differential bevel gear shaft into final position and secure with spring pin.