Differential: Service and Repair

Differential

Special tools, testers and auxiliary items required

• Tapered Roller Bearing Puller (V.A.G 1582)

• Attachment to VAG 1582 (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 (40-200 Nm) (V.A.G 1332)

• Kukko Extractor 46-58 mm (21/7)

• Kukko Support (22/2)

Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing





- Remove the sleeve for the seal/flange shaft beforehand.

Installing the Outer Race/Tapered Roller Bearing into the Clutch Housing





There is no adjusting shim on the side of the clutch housing.

Removing the Bearing Inner Race/Tapered Roller Bearing





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

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

Installing the Bearing Inner Race/Tapered Roller Bearing





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

Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing





A Counter support, for example, Kukko support (22/2)
B Internal puller 46 to 58 mm, for example, Kukko extractor 46-58 mm (21/7)

Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing





- Install the adjusting shim under the outer race.

- Support the transmission housing using the press support-R&I wheel brg's (3144) directly under the bearing mount.

Differentiating the Roll Pins










Allocation, Differential Housing





- Check the roll pin hole in the differential housing.

The hole in the differential housing was modified due to the longer roll pin.






Roll Pin with Groove (short roll pin): Removing and Installing





Removing

- Cover the taper roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.

- Remove the roll pin using a chisel.

Installing

- Drive into the differential housing up to the stop.

Roll Pin without a Surrounding Groove (long roll pin), Removing: Press out the Differential Bevel Gear Axle





Roll pin is sheared off when it is removed.

- Drive the remaining part of the roll pin out of the differential housing.

Roll Pin without a Surrounding Groove (long roll pin), Installing





- Align the hole in the differential bevel gear axle to the hole in the differential housing.

- Drive a new roll pin in, to dimension - a - = 3.0 mm using a drift - 1 -.

• The roll pin must not come in contact with the transmission when the differential housing is installed.

On some Transmissions, the Thrust Washer Union has a Ridge - A -.





Also, the differential housing has a groove - B - all the way around it.

- Insert the thrust washer union using transmission fluid.

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

Installing the Differential Planetary Gears and Differential Bevel Gear Axle





- Insert the thrust washer union using transmission fluid.

- Install and secure both large differential planetary gears, for example, with a flange shaft.

- Insert the small differential planetary gears 180° offset and pivot them into position.

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

- Insert the threaded pieces - arrow B - into the large differential planetary gears.

Installed position: Collar toward the differential bevel gear

- Drive the differential planetary gear axle into final position and secure with a roll pin.

Installed Position: Tapered Ring Thrust Washer - 1 -





The collar - arrow - faces the pressure spring - B -.

Some transmissions are not equipped with ridges - A -.

The ridges - A - face the tapered ring - 1 -.