Differential, Disassembling and Assembling
Differential, disassembling and assembling, 01V, 5 SPD. A/T (AWD)
Special tools, testers and auxiliary items required:
^ Needle bearing drift VW295
^ Thrust plate VW401
^ Thrust plate VW402
^ Punch VW407
^ Punch VW408A
^ Thrust disc VW412
Special tools, testers and auxiliary items required:
^ Thrust pad VW442
^ Sleeve 40-21
^ Thrust piece 40-105
^ Thrust plate 2050
^ Drift 3138
^ Torque wrench 40-200NM V.A.G 1332
Special tools, testers and auxiliary items required:
^ Taper roller bearing puller V.A.G1582
^ Attachment V.A.G1582/6
^ Kukko puller 120mm max 44/2
Heat inner race/tapered roller bearing to 100°C before installing.
Always replace both taper roller bearings together as a set.
Differential must be adjusted when replacing tapered roller bearings, differential housing, rear final drive cover, gear set and transmission housing.
Clamp rear final drive in assembly fixture
^ Adjustment work is necessary when replacing these parts.
1. Cover for rear final drive
2. O-ring
^ Always replace
^ Lubricate with oil when installing
3. Rear axle housing
4. Shim S1
^ Note thickness
5. Small outer race/tapered roller bearing
^ Driving out
^ Pressing in
6. Small inner race/tapered roller bearing
^ Pulling off
^ Pressing on
7. Hex bolt, 60 Nm and turn an additional 45°
^ Always replace
^ Lightly fasten bolts, then tighten in a diagonal sequence to torque specification
^ Allocation Original parts distributor
8. Differential housing
9. Ring gear see note
^ Mated with drive pinion (final drive set)
^ drive off using drift
^ Install on differential housing
^ Allocate according to transmission code letters via original parts distributor.
10. Roll pin
^ For securing the axle for differential bevel gears
^ Drive in flush
11. Large inner race/tapered roller bearing
^ Pulling off
^ Pressing on
12. Large outer race/tapered roller bearing
^ Driving out
^ Pressing in
13. Shim S2
^ Note thickness
14. Threaded piece
15. Large differential bevel gear
16. Small differential bevel gear
17. Axle for differential bevel gears
^ Drive out using drift
18. Shim
^ Determining thickness
19. Thrust washer
^ Check for cracks
Clamp rear final drive in assembly fixture
Driving small tapered roller bearing/outer race out of housing
^ After removing, check shims for damage.
Pressing small tapered roller bearing/outer race into housing to stop
Pulling off small inner race/tapered roller bearing
A - standard two-arm puller, e.g. Kukko puller 120mm max 44/2
Pressing on small tapered roller bearing inner race
CAUTION: Wear protective gloves!
^ Heat inner race to approximately 100°C before pressing on
Pulling off large inner race/tapered roller bearing
^ Before installing puller, set thrust piece 40-105 onto differential housing.
Pressing on large inner race/tapered roller bearing
CAUTION: Wear protective gloves!
^ Heat inner race to approximately 100°C before pressing on
Driving off outer race/tapered roller bearing from cover
^ After removing, check shims for damage.
Pressing outer race/tapered roller bearing into cover
Drive ring gear from housing
Install ring gear
CAUTION: Wear protective gloves!
^ Heat ring gear to approximately 100°C and install.
^ When installing ring gear, guide with centering pins - A - (self-made).
Installing small differential bevel gears
^ If the large differential bevel gears were replaced, adjustment shims must be re-determined.
^ Insert large differential bevel gears with determined adjustment shims.
^ Install small differential bevel gears at 180° from their final position and rotate into place - arrow -.
^ Install and align thrust washers.
^ Insert threaded pieces, be sure to fit properly.
^ Drive the axle for differential bevel gears into final position and secure.
Differential bevel gears, adjusting
^ Insert large differential bevel gears with 0.5 mm thick adjustment shims.
^ Install small differential bevel gears offset by 180° together with thrust washers.
Make sure that thrust washers are now no longer swapped.
^ Drive in axle for differential bevel gears.
^ Press small differential bevel gears outward.
^ Push the large differential bevel gears - in direction of arrow - and check backlash.
^ Determine the largest possible shim that can still be installed for the large differential bevel gears on each side.
^ Select shims with same thickness.
Table of adjustment shims
Allocate adjustment shims via original parts distributor.
If no backlash can be measured, differential bevel gears are just able to still be turned, the adjustment is also OK