Differential, Disassembling and Assembling
Differential, disassembling and assembling, 01A, 5 SPD. M/T (AWD)
Special tools, testers and auxiliary items required:
^ Pressure plate VW 401
^ Pressure plate VW 402
^ Punch VW 407
^ Punch VW 408 A
^ Thrust pad VW 447 H
^ Thrust pad VW 447i
Special tools, testers and auxiliary items required:
^ Thrust pad VW 472/1
^ Thrust plate 2050
^ Drift 3138
^ Sleeve 3144
^ Tube 3296
^ Torque wrench 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, beating seat for left tapered roller beating on differential housing was equipped with a larger radius at inner stop. Inner race of left tapered roller beating was also modified accordingly. Tapered roller beatings of the old construction type can no longer be installed along with new differential housing. Allocation Electronic Parts Catalog (ETKA).
^ Replace both tapered roller beatings together.
^ Adjustments are required when replacing components marked with 1).
1. Transmission housing 1)
2. Adjustment shim "S2"
^ Note thickness
3. Outer race for right tapered roller bearing
^ Driving out
^ Pressing in
4. Inner race for right tapered roller bearing
^ Pull off
^ Pressing on
5. Ring gear
^ Is matched to pinion shaft (gear set)
^ Allocate according to transmission code via Electronic Parts Catalog (ETKA) Code letters, transmission application, ratios, capacities
^ Press off of housing using drift
^ Install on differential housing
6. Differential housing 1)
^ As of 08.98, reinforcement measures (gradual introduction)
^ Left bearing seat modified as of 05.03
^ Allocate according to transmission code via Electronic Parts Catalog (ETKA)
7. Bolt, 60 Nm plus an additional 45° (1/8 turn)
^ Replace
^ Lightly tighten bolts then tighten diagonally to correct torque.
8. Inner race for left tapered roller bearing 1)
^ As of 08.98, reinforcement measures (gradual introduction)
^ Tapered roller bearing modified as of 05.03
^ Allocate according to transmission code via Electronic Parts Catalog (ETKA)
^ Pulling off
^ Pressing on
9. Drive gear for speedometer
^ Install onto differential carefully and without canting. Do not exert force, sensor wheel may break
10. Outer race for left tapered roller bearing
^ Driving out
^ Pressing in
^ As of 08.98, reinforcement measures (gradual introduction)
^ Drive in using pressure piece 2050 and VW 408 A
^ Tapered roller bearing modified as of 05.03
^ Allocate according to transmission code via Electronic Parts Catalog (ETKA)
11. Adjustment shim "S1"
^ Note thickness
^ Allocate according to Electronic Parts Catalog (ETKA)
12. Cover for final drive 1)
^ As of 08.98, reinforcement measures (gradual introduction)
^ Allocate according to Electronic Parts Catalog (ETKA)
^ Coat sealing surfaces thinly with sealant AMV 188 00102
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 for right 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 for right tapered roller bearing into transmission housing
^ Insert pressure piece VW 472/1 together with cone in outer race.
Pulling off right tapered roller bearing inner race
A - Two arm puller, e.g. Kukko 20/10 or Kukko 44/2
Note:
^ The differential 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 gear 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 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 gear to approximately 100°C, install and press on.
Driving outer race for left tapered roller bearing out of 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 for left tapered roller bearing into cover on transmissions without reinforcement measures
^ Insert pressure piece VW 472/1 together with cone in outer race.
Driving in outer race for left tapered roller bearing into cover on transmissions with reinforcement measures as of 08.98
^ Outer race for left tapered roller bearing must be pressed into cover using pressure piece 2050.
^ Insert pressure piece 2050 together with cone in outer race.
Driving out ring gear from housing
Heat ring gear to approximately 100°C and insert
^ When installing ring gear, guide with centering pins - A - (self-made).
CAUTION: Wear protective gloves!
^ Allow to cool off slightly before screwing in mounting bolts. Then tighten to tightening 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 - arrow - at 180° from their final position and rotate into place.
^ 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.