Differential, Disassembling and Assembling
Differential, disassembling and assembling, 02J, 5 Spd. M/T
Special tools and equipment:
^ VAG 1582 Puller
^ VAG 1582/3 Grip
^ VW 412 Press tool
^ 40-105 Thrust plate
^ VW 401 Thrust plate
^ VW 402 Thrust plate
Special tools and equipment:
^ VW 408 A Press tool
^ VW 473 Thrust piece
^ 30-205 Thrust plate
^ 3144 Sleeve
^ 2007 Thrust pad
Note:
^ Heat tapered roller bearing inner race to 100°C before installing.
^ Always replace both tapered roller bearings together as a set.
^ If differential housing, transmission housing or clutch housing tapered roller bearings are replaced adjust differential.
1 - Transmission housing
2 - Bolt
3 - Differential cage
^ Bolt to final drive gear
4 - Final drive gear
^ Riveted in production
^ Paired with output shaft, only replace as a set
^ Pressing off go to Fig. 9
^ Installation position go to Fig. 10
^ Heat to 100°C before installing
^ Mount to differential housing go to Fig. 11
^ Attaching with bolts go to Fig. 12
5 - Backing plate
6 - Nut, 70 Nm
7 - Shim
^ For differential
8 - Tapered roller bearing outer race
^ Driving out go to Fig. 5
^ Pressing in go to Fig. 6
9 - Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
10 - Differential housing
^ With riveted final drive gear
^ When replacing final drive gear drill out rivet heads go to Fig. 8
^ Attaching final drive gear with bolts go to Fig. 12
11 - Speedometer drive wheel
^ Fit onto differential housing as far as stop before pressing on inner race
12 - Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
13 - Tapered roller bearing outer race
^ Driving out go to Fig. 1
^ Pressing in go to Fig. 2
14 - Clutch housing
15 - Sleeve
^ Installed in conjunction with springs behind flange shafts
^ To accept oil seal (item 16)
16 - Oil seal
17 - Counter-sunk head bolt, 25 Nm
^ Bolt into threaded piece (item 25)
18 - Flange shaft
19 - Spring for flanged shaft
^ Installed behind flange shafts
20 - Thrust washer
^ Installation position: Shoulder toward spring, tongue to tapered ring
21 - Tapered ring
^ With grooves to secure thrust washer
^ Installation position: Taper faces differential housing
22 - Circlip
^ Ensures tapered ring, thrust washer and spring are held in position when flange shaft is removed
23 - One-piece thrust washer
^ Coat with gear oil when installing
24 - Differential side gear
^ Installing go to Fig. 14
25 - Threaded piece
^ Installing go to Fig. 14
26 - Differential pinion shaft
^ Drive out with a drift
^ Installing go to Fig. 14
27 - Spring pin
^ For securing differential pinion shaft
^ Removing and installing go to Fig. 13
28 - Differential pinion gear
^ Installing go to Fig. 14
29 - Differential side gear
^ Installing go to Fig. 14
Fig. 1 Driving tapered roller bearing outer race out of clutch housing
- Remove flange shaft seal mounting sleeve on transmissions with springs behind flange shaft.
Fig. 2 Pressing tapered roller bearing outer race into clutch housing
No shim is installed in the clutch housing end.
Fig. 3 Pulling off tapered roller bearing inner race
- Before fitting extractor position press piece 40-105 on differential housing.
Note: Both tapered roller bearing inner races are pulled off the differential housing in the same way.
Fig. 4 Pressing on tapered roller bearing inner race
Note: The tapered roller bearing inner races for the transmission housing and clutch housing are pressed on with the same press tools.
Fig. 5 Pulling tapered roller bearing outer race out of transmission housing
A - Counter support, e.g. Kukko 22/2
B - Internal puller 46... 58 mm, e.g. Kukko 21/7
Fig. 6 Pressing tapered roller bearing outer race into transmission housing
- Install shim under outer race.
- Support transmission housing with sleeve 3144 directly below bearing mounting.
Fig. 7 Both sides of differential housing are chamfered (arrow) to accept tapered rings/springs
Fig. 8 Drilling out rivet heads
- Drill out rivet heads with 12 mm drill from countersunk side and drive out with a drift.
Note: Clean differential before and after drilling and protect tapered roller bearing from drillings.
Fig. 9 Pressing off final drive gear
- Place thrust piece 40-105 on differential housing.
Fig. 10 Installation position of final drive gear
The circular groove -A- faces bolt-on side of differential.
Fig. 11 Heating final drive gear to approximately 100°C and installing
- Use bolts -A- from repair kit to guide final drive gear into position during installation.
Fig. 12 Bolting final drive gear and differential housing together
Use special bolts with plates and nuts according to parts catalog.
Fig. 13 Removing and installing differential pinion shaft spring pin
Removing
- Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.
- Insert chisel into circumferential groove and drive out spring pin.
Installing
- Drive fully into the differential housing.
Fig. 14 Installing differential side gears and pinion gears
- Lubricate one piece thrust washer with gear oil and install.
- Install both side gears and secure (e.g. with flange shaft).
- Insert pinion gears (180° apart) and pivot into position.
- Push pinion shaft (arrow -A-) in until first pinion gear is contacted.
- Position threaded pieces (arrow -B-) in side gears.
Installation position: step faces side gear
- Drive pinion shaft into final position and secure with spring pin.