Differential: Service and Repair
Differential
Special tools, testers and auxiliary items required
• Pressure Plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Thrust Disc (VW 412)
• Press Tube (30 - 23)
• Thrust Piece (40-105)
• Thrust Pad (3005)
• Tube (3259)
• Tube (3296)
• Assembly Tool (3301)
• Press Tool (3345)
• 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)
• Kukko Puller (204/2)
• Extractor Lever (VW 681)
• Pulling Hook (T20143/2)
• Thrust Piece (T40007)
• Heat inner race/tapered roller bearing to 100 °C (212 °F) before installing.
• Replace both tapered roller bearings together.
• Adjust differential, refer to => [ Differential, Adjusting ] Differential, Adjusting when replacing tapered roller bearing, differential housing, transmission housing or clutch housing.
1 Transmission Housing
2 Adjusting Shim
• For the differential
• To select the correct thickness, refer to => [ Differential, Adjusting ] Differential, Adjusting
3 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Outer Race/Tapered Roller
Bearing from the Transmission Housing ]
• Installing, refer to => [ Installing Outer Race/Tapered Roller
Bearing into the Transmission Housing ]
4 Bearing Inner Race/Taper Roller Bearing
• Removing, refer to => [ Removing the Bearing Inner Race/Taper
Roller Bearing ]
• Installing, refer to => [ Installing the Bearing Inner Race/Taper
Roller Bearing ]
5 Differential Housing
• With riveted final drive gear
6 Bearing Inner Race/Taper Roller Bearing
• Removing, refer to => [ Removing the Bearing Inner Race/Taper
Roller Bearing ]
• Installing, refer to => [ Installing the Bearing Inner Race/Taper
Roller Bearing ]
7 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Outer Race/Tapered Roller
Bearing from the Clutch Housing ]
• Installing, refer to => [ Pressing Outer Race/Tapered Roller
Bearing with Shim into Clutch Housing. ]
8 Washer
Installed position: The collar on the inner circumference faces the seal.
Allocation, refer to the Parts Catalog
9 Clutch Housing
10 Seal
• Between manual transmission and bevel box
• Remove with (VW 681) or (T20143/2)
• Can be driven in to stop on disassembled transmission with (T40007)
11 Seal
• For the right flange shaft
• The left and right diameters are different
12 Hex Bolt - item 17 - => [ (Item 17) Bolt ]
13 Conical Head Bolt
• 33 Nm
• Install with the threaded piece - item 24 - => [ (Item 24) Threaded Piece ]
14 Right Flange Shaft
15 Seal
• Remove to replace needle bearing (polygon bearing - item 16 - => [ (Item 16) Needle Bearing (polygon bearing) ] )
16 Needle Bearing (polygon bearing)
17 Locking Ring
• Always replace
18 Bevel Box
19 Seal
• Between bevel box and manual transmission
20 large Differential Bevel Gear
• Installing, refer to => [ Installing the Differential Bevel Gears ]
21 Differential Taper Axle
• Removing, refer to => [ Removing the Differential Bevel Gear
Axle and Spring Pin ]
• Installing, refer to => [ Installing the Differential Bevel Gears ]
22 Adapter Sleeve
• For securing the axle for differential bevel gears
• Removing, refer to => [ Removing the Differential Bevel Gear
Axle and Spring Pin ]
• Drive new roll pin in flush, refer to => [ Roll Pin, Installing ]
23 Small Differential Bevel Gear
• Removing and installing, refer to => [ Installing the Differential Bevel Gears ]
24 Threaded Piece
• Installing, refer to => [ Installing the Differential Bevel Gears ]
25 Thrust Washer Union
• Install with transmission fluid
26 Locking Ring
• Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed
27 Tapered Ring
• With grooves for the thrust washer
• Installed position: differential housing taper
28 Thrust Washer
• Installed position: Collar towards spring, tab toward tapered ring
29 Left Flange Shaft Spring
• Installed behind left flange shaft
30 Left Flange Shaft
31 Seal
• For the left flange shaft
• the left and right diameters are different
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
A Counter-support , for example, (Kukko 22/2)
B Internal puller 46 to 58 mm , for example, (Kukko 21/7)
- Tension the internal puller - B - between the outer race/tapered roller bearing and the shim.
• Check the washer for damage after removing it and replace if necessary.
Pressing Outer Race/Tapered Roller Bearing with Shim into Clutch Housing.
• Pay attention to the shim installed position.
• The collar on the inner circumference faces the seal.
Removing the Bearing Inner Race/Taper Roller Bearing
- Place the (40-105) on the differential housing.
- Tension the Kukko puller , for example (204/2) , under the bearing inner race near the flat side of the differential housing.
• When removing the bearing inner race, make sure the hooks do not bend outward; if necessary tighten bolt - arrow -.
Installing the Bearing Inner Race/Taper Roller Bearing
Removing the Bearing Inner Race/Taper Roller Bearing
A Kukko Puller 65-160 mm , for example, (18/1)
B Kukko Separating Tool 12-75 mm , for example, (17/1)
Installing the Bearing Inner Race/Taper Roller Bearing
- Mount assembly tool 3 (3301/3) from (3301) with the recess - arrow - (larger inner diameter) on the bearing inner race/tapered roller bearing.
Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
A Kukko support , for example, (22/2)
B Kukko extractor 46-58 mm , for example, (21/7)
Installing Outer Race/Tapered Roller Bearing into the Transmission Housing
- Support the transmission housing directly under the bearing mount using the (3345).
Removing the Differential Bevel Gear Axle and Spring Pin
- Install the adapter sleeve - 1 - in the differential bevel gear axle - 2 - so that it is flush.
- Mount the differential under the press with the adapter sleeve - arrow - facing the (30 - 23).
- Remove the differential bevel gear axle.
• Remove sheared parts of roll pin from differential bevel gear axle if necessary.
Installing the Differential Bevel Gears
- Insert thrust washer union with 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
- Drive differential planetary gear axle into final position and secure with spring pin. Refer to => [ Roll Pin, Installing ].
Roll Pin, Installing
- Install the new adapter sleeve - arrow - flush with the differential housing using a needle bearing drift - 1 -.