Cover For Torsen Differential, Servicing; Torsen Differential, Removing and Installing

Cover for Torsen differential, servicing; Torsen differential, removing and installing, 01A, 5 SPD. M/T (AWD)

Special tools, testers and auxiliary items required:

^ Pressure plate VW 401
^ Pressure plate VW 402
^ Punch VW 407
^ Thrust Disc VW 412
^ Guide Pin VW 439
^ Thrust piece 3002

Special tools, testers and auxiliary items required:

^ Tube VW 416 B
^ Seal driver-frt wheel bearing 40 - 21
^ Tube VW 519
^ Tube 2040
^ Slide hammer VW 771
^ Adapter VW 771/15
^ - 3 -Separating tool Kukko 17/2





1. Transmission cover
2. Compression spring
3. Front needle bearing
^ Removing
^ Installation position
^ Pressing in

4. Torsen differential
^ Do not disassemble
^ Remove after removing flange shaft
^ Replace if damaged
^ Pressing in

5. Rear needle bearing
^ Removing
^ Installation position
^ Pressing in

6. Ball bearing
^ For Torsen differential
^ Pressing off
^ Pressing on

7. Circlip
8. Circlip
^ Remove and install along with flange shaft

9. Ball bearing
^ For flange shaft
^ Removing
^ Pressing in

10. Cover
11. Circlip
12. Cap
^ Removing

13. O-ring
^ Always replace
^ Insert with grease

14. Torx bolt, 25 Nm
15. Seal
^ Pull out using extractor lever VW 681
^ Driving in

16. Vibration damper
17. Circlip
18. Torx bolt, 35 Nm
^ Self-locking
^ Always replace

19. Drive flange
^ Removing and installing





Removing sealing cap
^ Remove circlip - A -.
^ Screw one M8 bolt into threaded hole of sealing cap - B -.
^ Pull out sealing cap - B - with bolt.





Drive flange, removal and installation

Removing
^ Spread circlip and pull out flange shaft while doing so.

Installing
^ When inserting flange shaft, circlip must be inserted with it simultaneously.
^ Circlip must be fully seated in groove.





Pressing out Torsen differential
^ Place thrust piece 3002 through hole - arrow - directly onto Torsen differential.





Pressing off ball bearing from Torsen differential
A - Separating device 22 to 115 mm, e.g. Kukko 17/2





Pressing on ball bearing on Torsen differential





Pressing out ball bearing for flange shaft





Pressing in ball bearing for flange shaft





Pulling out needle bearing

A - Internal puller 22 to 28 mm, e.g. Kukko 21/4.

^ Both needle bearings in Torsen differential are pulled out with same internal extractor.





Installation position of front needle bearing

Dimension - a - = 32.5 mm





Installation position of rear needle bearing

Dimension - a - = 14 mm





Pressing in needle bearing
^ Both needle bearings in Torsen differential are pressed in with same special tool.





Pressing in Torsen differential





Driving in sealing ring

Installation position:

2 mm under surface of cover