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 Tube (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)
• Secure the transmission to the assembly stand. Refer to => [ Transmission, Securing to the Engine/Transmission Holder ] Transmission, Securing to the Engine/Transmission Holder.
• Heat the inner race/tapered roller bearing and the ring gear to 100 °C (212 °F) using the inductive heat unit (VAS 6414) , or equivalent, before installing.
• Adjust the differential, refer to => [ Differential, Adjusting ] Differential, Adjusting, when replacing tapered roller bearings, the differential housing, the transmission housing or the 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
• Removing, refer to => [ Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing ].
• Installing, refer to => [ Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing ].
4 Inner Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Inner Race/Tapered Roller Bearing ].
• Installing, refer to => [ Installing the Inner Race/Tapered Roller Bearing ].
5 Differential housing
• With a riveted final drive gear.
6 Inner Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Inner Race/Tapered Roller Bearing ].
• Installing, refer to => [ Installing the Inner Race/Tapered 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 the Outer Race/Tapered Roller Bearing with Washer into the Clutch Housing ].
8 Washer
• Installed position: The shoulder on the inner circumference faces the seal - item 13 -.
• Allocation, refer to the Parts Catalog.
9 Clutch Housing
10 Bolt
• 33 Nm
• Install with the threaded piece - item 22 -.
11 Right Flange Shaft
12 Ring
• Pry the ring off the flange shaft (- item 11 -) with a screwdriver.
• Installed position: The depression faces away from threaded holes in the flange shaft.
• Install the ring all the way by hand.
• The ring must lock into the flange shaft.
13 Seal
• For the right flange shaft
• Allocation, refer to the Parts Catalog.
• Replace with the transmission installed. Refer to => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
14 Flange Shaft Pressure Spring
• Installed behind the flange shaft.
15 Thrust Washer
• Installed position: The collar to the compression spring, braces (if installed) to the tapered ring.
16 Tapered Ring
• Installed position: Differential housing taper.
17 Lock Ring
• Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed.
18 Large Differential Bevel Gear
• Installing, refer to => [ Installing the Differential Bevel Gears ].
19 Differential Taper Axle
• Remove using a drift.
• Installing, refer to => [ Installing the Differential Bevel Gears ].
20 Roll Pin
• Secures the differential bevel gear axle.
• Removing and installing, refer to => [ Removing and Installing the Roll Pin for the Differential Bevel Gear Axle ].
21 Small Differential Bevel Gear
• Installing, refer to => [ Installing the Differential Bevel Gears ].
22 Threaded Piece
• Installing, refer to => [ Installing the Differential Bevel Gears ].
23 Thrust Washer Union
• Install using transmission fluid.
24 Ring
• Pry the ring off the flange shaft (- item 25 -) with a screwdriver.
• 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.
25 Left Flange Shaft
26 Seal
• For the left flange shaft.
• Allocation, refer to the Parts Catalog.
• Replace when the transmission is 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)
• Check the washer (- item 8 - in the => [ Differential ] Service and Repair) for damage after removing it and replace if necessary.
Pressing the Outer Race/Tapered Roller Bearing with Washer into the Clutch Housing
- Install the washer beforehand.
• Pay attention to the installed position of the washer (- item 8 - in the => [ Differential ] Service and Repair).
• The collar on the inner circumference faces the seal.
Removing the Inner Race/Tapered Roller Bearing
- Before installing the puller, mount the thrust piece (40-105) onto the differential housing.
Installing the Inner Race/Tapered Roller Bearing
Removing the 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 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 tube (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 drift.
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 the threaded pieces - arrow B - into the large differential planetary gears.
Installed position: The collar goes toward the differential bevel gear.
- Install the differential bevel gear axle up the end position and secure it with a new roll pin.