Differential, Removing and Installing

Differential, removing and installing, 01A, 5 SPD. M/T (AWD)

Special tools, testers and auxiliary items required:

^ Slide Hammer-Complete Set VW771
^ 27 mm socket insert 3257
^ Torque wrench V.A.G. 1331
^ - 1 - Internal extractor Kukko 21/3

Note:
^ Removal and installation is also possible with transmission installed.
^ The differential can be installed and removed without removing shift mechanism, drive flange and pinion shaft. Removal of the components mentioned above is necessary if the differential must be adjusted.
^ Look for visible damage of polygon beatings.
^ Polygon beatings can only be replaced together with drive flange.
^ Rough running of the polygon beatings with the drive flange removed is no sign for faulty beatings. An acoustic test can only be performed in installed condition.
^ A spacer ring is installed between the polygon beating and differential pinion for drive flanges with a spline diameter of 30 mm, - item 5 -.
^ Adjustments are required when replacing components marked with 1).





1. Transmission housing 1)
2. Seal
3. Circlip
^ Replace
^ Removing and installing

4. Spacer ring ^Inserted only in conjunction with flange shafts with 30 mm spline diameter
5. Drive flange
^ Flange shaft assembly

6. Differential with ring gear
^ As of 08.98, reinforcement measures (gradual introduction)

7. Cover for final drive 1)
^ Coat sealing surfaces thinly with sealant AMV 188 00102
^ As of 08.98, reinforcement measures (gradual introduction)

8. Torx bolt, 25 Nm
9. Drive gear for speedometer
^ Install onto differential carefully and without canting. Do not exert force, sensor wheel may break





Removing and installing securing ring
^ Clamp flanged shaft in vise with protective jaws. Press circlip with new circlip - A - out of flanged shaft groove.





Removing spacer ring

A - Internal puller 18.5 to 23.5 mm, e.g. Kukko 21/3
^ If spacer ring is tight, remove using slide hammer-complete set VW 771.





Installing spacer ring
^ Press in spacer ring to stop without canting.





Flange shaft assembly
1. Drive flange
2. Needle bearing (polygon bearing)
3. Spacer ring
4. Spacer ring (is installed if spline diameter is 30 mm)
5. Circlip

Note: Needle beatings (polygon beatings) are difficult to move with flange shaft removed. This is no indication of faulty beatings.





Reinforcement measures as of 08.98 (tapered roller bearings with larger interior and exterior diameters) on left side of differential (ring gear side). Gradual introduction began as of transmission manufacture date 17 08 8, however in effect for all transmissions as of transmission manufacture date 11 01 9.

These modifications affect the following components:
1. Differential housing
2. Tapered roller bearing inner race
3. Tapered roller bearing outer race
4. Adjustment shim S1
5. Cover for final drive