Differential, Disassembling and Assembling
Differential, disassembling and assembling, 01M, 4 Spd. A/T
Special tools and equipment required:
^ VW 402 Thrust plate
^ VW 408 A Press tool
^ VW 411 Press tool
^ 30-205 Thrust plate
^ 40-21 Press tool
^ VAG 1582 Tapered roller bearing puller
Special tools and equipment required:
^ VW 191
^ VW 472/1 Thrust piece
^ VW 472/2 Thrust piece
^ VW 792 Thrust piece
^ 3347 Assembly tool
^ 2010
Special tools and equipment required:
^ VW 433 Thrust piece
^ V.A.G 1582/6 Grip
^ V.A.G 1582/6A Grip
^ VAG 1582/11 Grip
^ Kukko 21/7 Internal puller
^ Kukko 22/2 Counter-support
VAG 1582/3 Clamping ring:
Note: For transmissions produced from 04.98, the tool for removing the tapered roller bearings in the final drive and differential is VAG 158218
^ 30-555 Thrust piece
Note:
^ Heat tapered roller bearing inner race to 100°C before pressing on.
^ Heat adjusting ring for tapered roller bearing to 100°C before pressing in tapered roller bearing outer race.
1 - Differential housing with riveted gear for final drive
^ Final drive gear is riveted onto differential housing and then machined
^ If differential or final drive gear is damaged, replace differential housing together with riveted final drive gear
^ Number of teeth on final drive gear
^ Differential housings differ depending on diameter of tapered roller bearings
2 - Output shaft/drive flange
3 - Tapered roller bearing inner race
^ There are different sizes of tapered roller bearings. Installed location can vary
^ Pulling off go to Fig. 1 and Fig. 3
^ Pressing on go to Fig. 2 (with equal sized bearings on both sides)
^ Pressing on go to Fig. 4
4 - Tapered roller bearing outer race
^ Remove and install only when adjusting ring is heated
^ Drive out with drift
^ Pressing in go to Fig. 6
5 - Bearing body for tapered roller bearing
^ There are different types of bearing body
^ Pulling off tapered roller bearing/inner race go to as Fig. 9
^ Pressing on go to Fig. 8
^ Pressing on go to Fig. 10
6 - O-ring
^ Always replace
7 - O-ring
^ Always replace
8 - Adjusting ring for tapered roller bearing
9 - Output shaft/drive flange
10 - Tapered roller bearing outer race
^ Remove and install only when adjusting ring is heated
^ Drive out with drift
^ Pressing in go to Fig. 6
11 - Tapered roller bearing inner race
^ There are different sizes of tapered roller bearings. Installed location can vary
^ Pulling off go to as Fig. 1 (with equal sized bearings on both sides)
^ Pressing on go to Fig. 2
^ Inserting go to Fig. 5
12 - Driver bushing
^ Drive off together with speedometer drive gear item -13-
^ Drive on with drift
13 - Speedometer drive gear
^ Drive out with a drift
^ Fit on together with driver bushing item -12-
14 - One-piece thrust washer
^ Place into differential cage before inserting bevel gears
15 - Small bevel gears
16 - Large bevel gears
^ Inserting go to Fig. 5
17 - Circlip
WARNING: Do not remove circlip until after pulling off drive flange as compression spring is pre-tensioned.
18 - Bevel gear shaft
^ Drive out with a drift
^ When driving in, do not damage one-piece thrust washer
19 - Spring pin
^ For securing bevel gear shaft
^ Removing and installing go to Fig. 11
Fig. 1 Pulling off tapered roller bearing inner race
Use adapter V.A.G 1582/6A for larger bearings
- Place press piece 30-555 on differential housing.
Note: For transmissions produced from 04.98, the tool for removing the tapered roller bearings in the final drive and differential is VAG 158218
Fig. 2 Pressing on tapered roller bearing inner race
Fig. 3 Pulling out tapered roller bearing outer race
Fig. 4 Pressing in tapered roller bearing outer race
Fig. 5 Inserting differential bevel gears
- Insert one-piece thrust washer with gear oil.
- Insert small bevel gears, drive in shaft and secure with spring pin.
- Insert large bevel gears offset 180° and swivel in direction of arrow.
Fig. 6 Pressing in tapered roller bearing outer race
- With adjusting ring or bearing body heated, insert outer race and press home up to stop.
Fig. 7 Pulling out tapered roller bearing outer race
A - Kukko 22/2 counter-support
B - Kukko 21/7 internal puller
Fig. 8 Pressing in tapered roller bearing outer race
Fig. 9 Pulling off tapered roller bearing inner race
- Place press piece VW 433 on bearing body.
Fig. 10 Pressing on tapered roller bearing inner race
Fig. 11 Removing and installing spring pin for bevel gear shaft
^ Length of spring pin: 28.5 mm
Removing
- Pull out spring pin with side cutting pliers.
Installing
- Drive in spring pin up to stop.