Differential: Service and Repair
Differential
Special tools, testers and auxiliary items required
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Thrust Piece (40-105)
• Thrust Pad (3005)
• Tube 60 mm Dia. (VW 415 A)
• Tube (3259)
• Tube (3296)
• Press Tool (3345)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to V.A.G 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)
• Heat the inner race/tapered roller bearing to 100 °C (212 °F) before installing.
• Replace both tapered roller bearings together.
• Adjust the differential, refer to => [ Differential, Adjusting ] Differential, Adjusting when replacing the tapered roller bearing, differential housing, transmission housing or clutch housing.
1 Transmission Housing
2 Adjusting Shim
• For the differential.
• Selecting the correct shim thickness, refer to => [ Differential, Adjusting ] Differential, Adjusting.
3 Outer Race/Tapered Roller Bearing
4 Bearing Inner Race/Tapered Roller Bearing
5 Differential Housing
• With a riveted final drive gear
• The mount - arrow - for the right tapered roller bearing with right flange shaft insert, is 12.5 mm longer.
Allocation, refer to the Parts Catalog.
6 Bearing Inner Race/Tapered Roller Bearing
7 Outer Race/Tapered Roller Bearing
8 Washer
Installed position: The collar on the inner circumference faces the seal.
Allocation, refer to the Parts Catalog.
9 Clutch Housing
10 O-ring
• Always replace.
11 Ring
• Not available in the US/Canadian market.
12 Bolt
• 33 Nm
• Install with the threaded piece - item 26 -.
13 Stub Shaft
• Not available in the US/Canadian market.
14 Seal
• Not available in the US/Canadian market.
15 Right Flange Shaft
Allocation, refer to the Parts Catalog.
16 Ring
• Pry the ring off the flange shaft - item 15 - with a screwdriver.
• Install the ring all the way by hand.
• The ring must lock into the flange shaft.
17 Seal
• Replace when the transmission is installed. Refer to => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
Allocation, refer to the Parts Catalog.
18 Compression Spring
• For the flange shaft.
• Installed behind the flange shaft.
19 Thrust Washer
• Installed position: Collar to compression spring, braces (if installed) to tapered ring.
20 Tapered Ring
• Installed position: differential housing taper.
21 Lock Ring
• Holds the tapered ring, thrust washer and compression spring in position when the flange shaft is removed.
22 Large Differential Bevel Gear
23 Differential Taper Axle
• Remove using a drift.
24 Roll Pin
• For securing the axle for the differential bevel gears.
25 Small Differential Bevel Gear
26 Threaded Piece
27 Thrust Washer Union
• Install using transmission fluid.
28 Ring
• Pry the ring off using a screwdriver alternating from side to side.
• Installed position: The depression faces away from threaded holes in flange shaft.
• Install the ring all the way by hand.
• The ring must lock into the flange shaft.
29 Flange Shaft
30 Seal
• For the flange shaft
Allocation, refer to the Parts Catalog.
• Replace with the transmission installed. Refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
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 washer.
Pressing the Outer Race/Tapered Roller Bearing with Washer into the Clutch Housing
• Pay attention to the washer installed position.
• The collar on the inner circumference faces the seal.
Removing the Bearing Inner Race/Tapered Roller Bearing
- Before installing the puller, install the thrust piece (40-105) onto the differential housing.
Installing the Bearing Inner Race/Tapered Roller Bearing
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 (Kukko 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
- Install 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 the final position and secure with the roll pin.