Differential: Service and Repair
Differential
Special tools, testers and auxiliary items required
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415 A)
• Thrust Piece (40-105)
• Thrust Pad (3005)
• Tube (3259)
• Tube (3296)
• Press Tool (3345)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to VAG 1582 (V.A.G 1582/6A)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Puller (65-160 mm) (18/1)
• Kukko Separating Tool 12-75 mm (17/1)
• Kukko Support (22/2)
• Inductive Heat Unit (VAS 6414)
Removing the Outer Race/Tapered Roller Bearing from the Clutch 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)
• Replace the shim - item 8 - in => [ Differential Overview ] Description and Operation after removing it.
Pressing the Outer Race/Tapered Roller Bearing with Shim into the Clutch Housing
- Install the old shim into the clutch housing.
• Pay attention to the shim installed position.
• The collar on the inner circumference faces the seal.
Removing the Bearing Inner Race/Tapered Roller Bearing
- Before installing the puller, mount the thrust piece (40-105) onto the differential housing.
Installing the Bearing Inner Race/Tapered Roller Bearing
The cage wit the tapered rollers must rotate easily when being installed.
Removing the Bearing Inner Race/Tapered Roller Bearing
A Puller, for example, Kukko puller 65-160 mm (18/1)
B Separating tool 12 to 75 mm, for example, Kukko separating tool 12-75 mm (17/1)
Installing the Bearing Inner Race/Tapered Roller Bearing
The cage wit the tapered rollers must rotate easily when being installed.
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
- Support the transmission housing directly under the bearing mount using the press tool (3345).
Removing and Installing the Roll Pin for the Differential Bevel Gear Axle
Removing
- Cover the inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.
- Remove the roll pin using a punch.
Installing
- Drive into the differential housing up to the stop.
Installing the Differential Bevel Gears
- 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 threaded pieces - arrow B - into the large differential planetary gears.
Installed position: Collar toward the differential bevel gear
- Install the differential bevel gear axle up the end position and secure it with a new roll pin.