Differential: Service and Repair
Differential
Special tools, testers and auxiliary items required
• Taper 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)
• Warm the bearing inner race/tapered roller bearing to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414) before installing. Wear protective gloves.
• Replace both tapered roller bearings together.
• Adjust the differential, refer to => [ Adjustment Overview ] Adjustment Overview when replacing the tapered roller bearings, differential housing, transmission housing or clutch housing.
1 Transmission Housing
2 Adjusting Shim
• For the differential.
• Determining thickness, refer to => [ Differential, Adjusting ] Differential, Adjusting.
3 Outer Race/Tapered Roller Bearing
• Removing.
• Installing.
4 Bearing Inner Race/Taper Roller Bearing
• Removing.
• Installing.
5 Differential Housing
• With the final drive gear.
• Thrust washer union fitted to differential housing.
• Spring pin hole adapted to the length of the spring pin.
• Allocate according to the Parts Catalog.
6 Bearing Inner Race/Taper Roller Bearing
• Removing.
• Installing.
7 Outer Race/Tapered Roller Bearing
• Removing.
• Installing.
8 Clutch Housing
9 Sleeve
• For mounting the seal - item 10 -.
• Removing and installing, refer to => [ Transmission Housing and Clutch Housing ] Transmission Housing and Clutch Housing.
10 Seal
• Left flange shaft seal, installing with transmission installed. refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
• Right flange shaft seal, installing with transmission installed (right flange shaft and sleeve seal consist of two parts) => [ Right Flange Shaft, Seal and Sleeve, Two Piece ] Right Flange Shaft, Seal and Sleeve, Two Piece.
11 Seal and Sleeve, One Piece
• If the seal is damaged, then replace both the seal and sleeve. Refer to => [ Right Flange Shaft, Seal and Sleeve, One Piece ] Right Flange Shaft, Seal and Sleeve, One Piece.
12 Bolt
• 25 Nm
• Install with the threaded piece - item 20 -.
13 Flange Shaft
• Removing and installing, refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
14 Flange Shaft Pressure Spring
• Installed behind the flange shaft.
15 Thrust Washer
• Installed position.
16 Tapered Ring
• With grooves for the thrust washer.
• 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 Thrust Washer Union
• Install using transmission fluid.
• The thrust washer union has a ridge on some transmissions.
19 Large Differential Bevel Gear
• Installing.
20 Threaded Piece
• Installing.
21 Differential Taper Axle
• Removing, with a short spring pin.
• Removing, with a long spring pin.
• Installing.
22 Adapter Sleeve
• To secure the differential bevel gear axle.
• Different lengths of spring pins are installed.
• Differentiating the spring pins.
• Short spring pin: removing and installing.
• Long spring pin: sheared off at removal.
• Long spring pin: installing.
23 Small Differential Bevel Gear
• Installing.
24 Large Differential Bevel Gear
• Installing.
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/Taper Roller Bearing
- Before installing the puller, set the (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/Taper 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, (22/2)
B Internal puller 46-58 mm, for example, (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 with the (3144) directly under the bearing mount.
Differentiating the Spring Pins
Allocation, Differential Housing
- Check the hole in the differential housing for the adapter sleeve.
The hole in the differential housing was modified due to the longer spring pin.
Roll Pin with Groove (short roll pin): Removing and Installing
Removing
- Cover the bearing inner race/tapered roller bearing and speedometer drive gear to prevent damage and to keep metal shavings from getting in.
- Remove the adapter sleeve using a chisel.
Installing
- Drive into the differential housing up to the stop.
Removing the Spring Pin without Surrounding Groove (long spring pin): Removing the Differential Bevel Gear Axle
Spring pin is sheared off when it is removed.
- Drive remaining part of roller pin out of differential housing.
Spring Pin without Surrounding Groove (long spring pin), Installing
- Align the hole in the differential bevel gear axle to the hole in the differential housing.
- Install the new adapter sleeve to dimension - a - = 3.0 mm using a mandrel - 1 -.
• The spring 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 thrust washer union with transmission fluid.
- Install the thrust washer union so that it fits into the groove - B - in the differential housing.
Installing the Differential Planetary Gears and Differential Bevel Gear Axle
- 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
- Install the differential bevel gear axle up the end position and secure it with a new spring 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 -.
MEX5R00632-060810