Differential Cover: Service and Repair

Torsen Differential Cover

Special tools, testers and auxiliary items required

• Seal remover (T40014)

• Pressure stand (T40099)

• Ice spray

• Protective gloves

Removing

• Input shaft removed. Refer to => [ Input Shaft ] Input Shaft.

- Pull the oil pipe - arrow - upward and out to avoid damage.





- Check all 8 screws - arrows - on the pressure stand (T40099).





• Screws must be installed flush to 25 Nm, refer to => Assembly instructions for pressure stand (T40099)..

- Insert input shaft in the pressure stand (T40099 ).





- Rotate the seal ring extractor (T40014) by hand into the shaft seal until the tool has a good hold in the shaft seal. Then tighten seal ring extractor (T40014) with an open end wrench.

- You can pull out the shaft seal a short distance by installing rear bolt - arrow -.

- Retighten the seal ring extractor (T40014) so that the puller engages securely in the shaft seal again and continue turning bolt to pull out the shaft seal.

- Repeat procedure until the shaft seal has been pulled out completely.

- Remove input shaft cover circlip - A -.





- Measure and note thickness of removed circlip.

• When installing, circlip must be replaced with a new circlip of same thickness.

- Clean cover sealing surface - arrow -.





CAUTION!
Wear protective gloves!

The ice spray can reach temperatures under 0° C which can freeze the skin without protective gloves.

- Cool the hollow shaft - 1 - on the inside of the ball bearing - 2 - seat - arrow 2 - over opening - arrow 1 - of removed oil pipe with ice spray, for example.





• Shaft represented in section here.

• Shaft must be cooled so that ball bearing - 2 - can be pressed off more easily and not be damaged.

- Clean surface of pressure stand (T40099).





- Insert input shaft in pressure stand (T40099 ).

• Input shaft sealing surface must be flush.

• There must be no objects such as cable ties or dirt between input shaft sealing surfaces and surface of pressure stand (T40099 ).

CAUTION!
Shavings or dirt damage cover sealing surfaces when pressed, cover must then be replaced.

- Also cool shaft from outside - arrow - with ice spray, for example.

• Shaft must be cooled so that ball bearing can be pressed off more easily and not be damaged.

- Place input shaft together with pressure stand ( T40099) on hydraulic press thrust plate.

• Pressure stand (T40099) should lie on as much surface of hydraulic press as possible.

- Hold shaft from below and at the same time, press shaft out of cover with hydraulic press.





- Place input shaft on assembly tool (T10219/1).





• Ignore screwdriver and arrows.

Installing

- Replace ball bearing in input shaft cover. Refer to => [ Input Shaft Cover Ball Bearing ] Input Shaft Cover Ball Bearing.

- Place input shaft cover on input shaft and press on by hand as far as possible.





- Place input shaft - B - on thrust plate (VW 401).





CAUTION!
Place input shaft straight and centered under hydraulic press thrust disc; otherwise input shaft can tip to the side when cover is pressed on.

- With hydraulic press, press input shaft cover - A - with tube (VW 416 B) onto input shaft up to stop.

Input shaft cover circlip, installing

- When installing, circlip - A - must be replaced with a new circlip of same thickness.





• Check for correct circlip seating.

Oil pipe, installing

- Check wear on transmission components. Refer to => [ Input Shaft Checking for Wear ] Testing and Inspection.

- Replace O-ring on oil pipe - 2 -.





• The oil pipe is pressed into the input shaft with the O-ring - 2 -.

• Oil pipe must engage noticeably, rotor blades - arrow A - on oil pipe must lie completely in input shaft.

- Press oil pipe - arrow - down into input shaft to stop.





• If oil pipe is inserted completely, the dimension from its end to the input shaft is approximately 11.5 mm.

If dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.

If dimension is larger, it is not pushed in far enough.

CAUTION!
• Input shaft must not be set down on the projecting oil pipe - arrow - otherwise it will be damaged.

• If the oil pipe is damaged, starting problems or a transmission malfunction will result.