Differential, Removing and Installing

Differential, removing and installing, 01M, 4 Spd. A/T

Special tools and equipment required:

^ VW 391 Axle shaft appliance
^ VW 681 Oil seal extractor
^ 3109 Puller
^ 3155 Ring nut spanner
^ 3319 Thrust piece





Note:
^ If tapered roller bearings are to be re-used, mark the adjusting ring go to Fig. 2
^ The drive pinion does not need to be removed for removing and installing the differential.

1 - Transmission housing
2 - Speedometer drive
^ With marking for oil level indication go to Fig. 4

3 - Output shaft/drive flange
^ Install thread facing drive flange
^ Remove before taking out differential
^ First adjust differential before installing

4 - O-ring
^ Always replace

5 - Adjusting ring
^ Removing go to Fig. 3
^ If used bearings are re-inserted, mark installed position and position on marking again when installing go to Fig. 2
^ When installing new bearing, pay attention to setting instructions go to Adjusting differential

6 - Oil seal for drive flange
^ Before installing, pack space between sealing lips with multi-purpose grease
^ Can be replaced with transmission installed
^ Remove with VW 681
^ Driving in go to Fig. 1

7 - Tapered ring
^ Shoulder faces thrust washer

8 - Thrust washer
^ Place over compression spring

9 - Compression spring
10 - Drive flange
^ Insert with tapered ring, thrust washer and compression spring
^ Remove before taking out inner circlip on bevel gear
^ Removing and installing go to Fig. 7

11 - Dished washer
12 - Circlip
13 - Cover
14 - Locking element
15 - Screw
^ 12 Nm

16 - Cover
17 - Circlip
18 - Dished washer
19 - Drive flange
^ Insert with tapered ring, thrust washer and compression spring
^ Remove before taking out inner circlip on bevel gear
^ Removing and installing go to Fig. 7

20 - Compression spring
21 - Thrust washer
^ Place over compression spring

22 - Tapered ring
^ Shoulder faces thrust washer

23 - Oil seal for drive flange
^ Before installing, pack space between sealing lips with multi-purpose grease
^ Can be replaced with transmission installed
^ Remove with VW 681
^ Driving in go to Fig. 1

24 - Bearing body
^ 150 Nm
^ Remove with 3155
^ Installing go to Fig. 5

25 - O-ring
^ Always replace

26 - Output shaft/drive flange
^ Install thread facing drive flange
^ Before removing, take out differential
^ First adjust differential before installing

27 - Differential
^ Before removing differential, take out bearing body, adjusting ring and output shafts

28 - Screw
^ 12 Nm

29 - Locking element
^ After adjusting tapered roller bearings, secure bearing body and adjusting ring.

30 - Circlip
^ First remove drive flange before removing circlip
^ Removing and installing go to Fig. 6

31 - Circlip
^ First remove drive flange before removing circlip
^ Removing and installing go to Fig. 6

32 - Seal
^ Always replace

33 - Cover
^ For differential

34 - Screw
^ 28 Nm
^ Insert with locking fluid AMV 185 101 A1





Fig. 1 Driving in drive flange oil seal up to stop





Fig. 2 Marking adjusting ring
- If used bearings are re-inserted, mark installed position (arrow) and again position on marking when installing.





Fig. 3 Removing adjusting ring





Fig. 4 Speedometer drive
- With transmission installed, check gear oil in final drive.





Fig. 5 Inserting differential and screwing in bearing body as far as stop to 150 Nm





Fig. 6 Inserting circlip (arrow)
- Remove circlip with two screwdrivers.





Fig. 7 Removing and installing drive flange

Removing
- Mount puller 3109 and remove circlip.
- Pull off drive flange with VW 391.

Installing
- Insert drive flange, dished washer and circlip.
- Pull drive flange in with 3109.

Note: Drive flange can also be pulled in with VW 391.

Vehicles with triple roller axle shafts
- Bolt puller Kukko 18-D to flange using two 8x35 mm bolts and 8 mm diameter washers.
- Pull off drive flange.