Differential, Disassembling and Assembling
Differential, disassembling and assembling, 01A, 5 SPD. M/T (AWD)
Special tools, testers and auxiliary items required:
^ Thrust Plate VW401
^ Thrust Plate VW402
^ Punch VW 407
^ Punch VW 412
^ Needle Bearing Drift VW295
^ Punch VW 408 A
Special tools, testers and auxiliary items required:
^ Thrust Pad VW442
^ Sleeve 40-21
^ Thrust piece 40 - 105
^ Thrust plate 2050
^ Drift 3138
^ Two arm puller Kukko 44/2
Special tools, testers and auxiliary items required
Tapered roller bearing puller V.A.G 1582:
Attachment V.A.G 1582/6:
Note:
^ General repair notes.
^ Clamp final drive in assembly fixture Rear final drive to assembly fixture, securing.
^ Replace both tapered roller bearings together.
^ Adjustments are required when replacing components marked with 1).
1. Cover for final drive 1)
2. O-ring
^ Replace
^ Insert with oil
3. Final drive housing 1)
4. Shim "S1"
^ Note thickness
5. Small tapered roller bearing outer race 1)
^ Driving out
^ Pressing in
6. Small tapered roller bearing inner race 1)
^ Pulling off
^ Pressing on
7. Bolt, 60 Nm plus an additional 45° (1/8 turn)
^ Replace
^ Lightly tighten bolts then tighten diagonally to correct torque.
8. Differential cage 1)
9. Ring gear 1)
^ Is matched to pinion shaft (gear set)
^ Allocation according to transmission code
^ Press off of housing using drift
^ Install on differential housing
10. Roll pin
^ For securing shaft for differential bevel gears
^ Drive in flush
11. Large tapered roller bearing inner race
^ Pull off
^ Pressing on
12. Large tapered roller bearing outer race
^ Driving out
^ Pressing in
13. Shim "S2"
^ Note thickness
14. Threaded piece
15. Large differential bevel gear
^ Installing
^ Adjusting
16. Small differential bevel gear
^ Installing
17. Shaft for differential bevel gears
^ Drive out using drift
18. Shim
^ Determining thickness
19. Thrust washer
^ Check for cracks
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 tapered roller bearing inner race
A - Two arm puller, e.g. Kukko 44/2
Pressing on small tapered roller bearing inner race
CAUTION: Wear protective gloves!
^ Heat inner race gear to approximately 100°C, install and press on.
Pulling off double tapered roller bearing inner race
^ Before installing puller, set thrust piece 40 - 105 onto differential housing.
Pressing on double tapered roller bearing inner race
CAUTION: Wear protective gloves!
^ Heat inner race gear to approximately 100°C, install and press on.
Driving large tapered roller bearing outer race out of cover
^ After removing check shims for damage.
Pressing in large tapered roller bearing outer race into cover
Driving out ring gear from housing
Installing ring gear
^ Use 2 centering pins - A - (self-made) as guide.
CAUTION: Wear protective gloves!
^ Heat inner race to approximately 100°C and insert.
Installing small differential bevel gears
^ If large differential bevel gears were replaced, adjustment shims must be redetermined.
^ 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 thrust washers and locate.
^ Install threaded pieces.
^ Drive in differential bevel gear shaft to final position and secure.
Adjusting small differential bevel gears
^ Install large differential bevel gears with thinnest shims (0.5 mm).
^ Install small differential bevel gears rotated by 180° together with thrust washers.
Note:
^ Do not rearrange differential bevel gears and thrust washers again!
^ Drive in shaft for differential bevel gears.
^ Press small differential bevel gears toward outside.
^ Push large differential bevel gears in direction of - arrow - and check backlash.
^ Determine largest possible shim that can still be installed for large differential bevel gears on each side.
^ Select adjustment shims of same thickness.
^ Determine adjustment shims according to table.
Available adjustment shims:
Note:
^ The adjustment is correct when no more play can be felt, but the differential bevel gears can just barely be rotated -arrow -.