Differential, Disassembling and Assembling
Differential, disassembling and assembling, 02M, 5 and 6 Spd. M/T
Special tools and equipment:
^ VW 353 Transmission support
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 408 A Press tool
^ VW 412 Press tool
Special tools and equipment:
^ 40-105 Thrust plate
^ 3005 Press disk
^ 3259 Tube
^ 3296 Tube
^ 3345 Tube
^ VAG 1332 Torque wrench or equivalent
Special tools and equipment:
^ VAG 1582 Tapered roller bearing puller
^ VAG 1582/6 Grip
^ 1 - Kukko 21/7 Internal puller
^ 4 - Kukko 22/2 Counter support
Note:
^ Heat tapered roller bearing inner race to 100°C before installing.
^ Always replace both tapered roller bearings together as a set.
^ If tapered roller bearings, differential housing, transmission housing or clutch housing are replaced, adjust differential.
1 - Transmission housing
2 - Bolt
3 - Differential cage
^ Bolt to final drive gear go to Fig 10
^ Use Parts catalog to check correct application
4 - Final drive gear
^ Riveted in production
^ Pressing off go to Fig. 8
^ Installed position- machined side faces bolting surface of differential housing
^ Heat to 100°C before installing
^ Install to differential housing go to Fig. 9
^ Bolted go to Fig. 10
5 - Backing plate
6 - Nut, 40 Nm and 1/8 turn (45°) further
7 - Clutch housing
8 - Shim
^ For differential
9 - Tapered roller bearing outer race
^ Pulling out go to Fig. 5
^ Pressing in go to Fig. 6
10 - Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
11- Differential housing
^ With riveted final drive gear
^ When replacing final drive gear drill out rivet heads go to Fig. 7
^ Attaching final drive gear with bolts go to Fig. 10
12 - Tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
13 - Tapered roller bearing outer race
^ Pulling out go to Fig. 1
^ Pressing in go to Fig. 2
14 - Shim
^ Always 0.65 mm thick
15 - Oil seal
^ For right flanged shaft
^ Left and right diameters differ
^ Use Parts catalog to check correct application
^ Replacing with transmission installed
16 - Counter-sunk head bolt, 25 Nm
^ Bolt into threaded piece (item 26)
17 - Left flanged shaft
^ Do not interchange, left and right flanged shafts differ
^ Use Parts catalog to check correct application
18 - Spring for flanged shaft
^ Installed behind flanged shafts
19 - Thrust washer
^ Installed position: shoulder toward spring, tongue to tapered ring
20 - Tapered ring
^ With grooves to secure thrust washer
^ Installed position: Taper toward differential housing
21 -Securing clip
^ Make sure that tapered ring, thrust washer and spring are held in position when flanged shaft is removed
22 - Large differential bevel gear
^ Installing go to Fig. 12
^ Use Parts catalog to check correct application
23 - Differential bevel gear shaft
^ Knock out with drift
^ Installing go to Fig. 12
^ Use Parts catalog to check correct application
24 - Spring pin
^ For securing differential bevel gear shaft
^ Use Parts catalog to check correct application
^ Removing and installing go to Fig. 11
25 - Small differential bevel gear
^ Installing go to Fig. 12
^ Use Parts catalog to check correct application
26 - Threaded piece
^ Installing go to Fig. 12
27 - One-piece thrust washer
^ Coat with transmission oil when installing
28 - Left flanged shaft
^ Do not interchange, left and right flanged shafts differ
^ Use Parts catalog to check correct application
29 - Oil seal
^ For left flanged shaft
^ Left and right diameters differ
^ Replacing with transmission installed
Fig. 1 Pulling tapered roller bearing outer race out of clutch housing
A - Counter support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Note: After puffing out, check washer for damage and replace if necessary.
Fig. 2 Pressing tapered roller bearing outer race into clutch housing
- First insert washer.
Fig. 3 Pulling off tapered roller bearing inner race
- Before mounting 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 to 58 mm, e.g. Kukko 21/7
Fig. 6 Pressing tapered roller bearing outer race into transmission housing
- Support transmission housing with tube 3345 directly below bearing mounting.
Fig. 7 Drilling out rivet heads
- Drill out rivet heads with 12 mm drill from countersunk side and drive rivet out with drift.
Note: Clean differential before and after drilling. Protect tapered roller bearing from metal particles.
Fig. 8 Pressing off final drive gear
- Place thrust piece 40-105 on differential housing.
Fig. 9 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. 10 Bolting final drive gear -A- and differential housing -B- together
Use special bolts -1- with backing plates -2- and nuts -3- according to Parts catalog.
Fig. 11 Removing and installing differential bevel gear shaft spring pin
Removing
- Cover tapered roller bearing inner race to avoid possible damage and ingress of metal particles.
- Knock out spring pin with chisel, inserting chisel into circumferential groove.
Installing
- Knock fully into differential cage.
Fig. 12 Installing differential bevel gears
- Lubricate one piece thrust washer with transmission oil and install.
- Install both large differential bevel gears and secure (e.g. with flanged shaft).
- Insert small differential bevel gears (180° apart) and pivot into position.
- Push differential bevel gear shaft (arrow -A-) in up to first small bevel gear.
- Position threaded pieces (arrow -B-) in large bevel gears.
Installed position: shoulder to bevel gear
- Drive differential bevel gear shaft into final position and secure with spring pin.