Differential

Differential

Special tools, testers and auxiliary items required

• Taper roller bearing puller (V.A.G 1582)

• Attachment (V.A.G 1582/3)

• Thrust disc (VW 412)

• Thrust plate (VW 401)

• Thrust plate (VW 402)

• Punch (VW 408 A)

• Thrust piece (VW 473)

• Thrust pad (30 - 205)

• Press support-R&I wheel brg's. (3144)

• Thrust pad (2007)

• Torque wrench 40 to 200 Nm (V.A.G 1332)

• Seal driver-frt wheel bearing (40 - 21)

• Thrust piece (40 - 105)

• Internal extractor (Kukko 21/7)

• Support (Kukko 22/2 )

Pressing tapered roller bearing outer race out from clutch housing





- Remove mounting sleeve for flange shaft seal first.

Pressing outer race/tapered roller bearing into clutch housing





No shim will be installed on side of clutch housing.

Pulling off inner races/tapered roller bearing





- Before installing puller, set thrust piece ( 40 - 105) onto differential housing.

• Both tapered roller bearing inner races are pulled off from the differential housing in the same way.

Pressing on inner races/tapered roller bearing





• Tapered roller bearing inner race for transmission housing and clutch housing are pressed on using the same special tools.

Pulling outer race/tapered roller bearing out of transmission housing





A Support, e.g. ( Kukko 22/2)
B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)

Pressing outer race/tapered roller bearing into transmission housing





- Insert shim under outer race.

- Support transmission housing directly beneath bearing mount using press support (3144 ).

Removing and installing roll pin for differential bevel gear axle





- Cover inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.

- Drive out roll pin using chisel. Place chisel in surrounding groove, to do so.

- Drive into differential housing until stop.

On some transmissions the thrust washer union was made with a ridge - A - in area of holes.





In conjunction with this, the differential housing had a circumferential groove - B -.

- Insert thrust washer union with gear oil.

- Install thrust washer union so that it engages into groove - B - of differential housing.

Installing differential planetary gears





- Insert thrust washer union with gear oil.

- Insert both large differential bevel gears and secure (e.g. with flange shaft).

- Install small differential bevel gears at 180 degrees from their final position and rotate into place.

- Press in differential bevel gear axle - arrow A - up to first small differential bevel gear.

- Insert threaded pieces - arrows B - into large differential planetary gears.

Installation position: Step facing toward differential planetary gear.

- Drive differential planetary gear axle into final position and secure with spring pin.

Installation position of thrust washer for tapered ring - 1 -





Collar - arrow - faces compression spring - B -.

Some transmissions are equipped with ridges - A -.

Ridges - A - face tapered ring - 1 -.