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 (VW 415 A)
• Thrust piece (40 - 105)
• Thrust pad (3005)
• Tube (3259)
• Tube (3296)
• Tube (3345)
• Taper roller bearing puller (V.A.G 1582)
• Attachment (V.A.G 1582/6A)
• Internal extractor (Kukko 21/7)
• Puller (Kukko 18/1)
• Separating tool (Kukko 17/1)
• Support (Kukko 22/2)
• Heat inner race/tapered roller bearing to approximately 100° C before installing.
• Always replace both taper roller bearings together as a set.
• Adjust differential --> [ Differential, Adjusting ] Differential, Adjusting, when replacing tapered roller bearing, differential housing, transmission housing or clutch housing.
1 Transmission housing
2 Shim
• For differential
• Determining thickness --> [ Differential, Adjusting ] Differential, Adjusting.
3 Tapered roller bearing outer race
• Pulling out --> [ Pulling Outer Race/Tapered Roller Bearing out of Transmission Housing ]
• Pressing in --> [ Pressing In Tapered Roller Bearing Outer Race into Transmission Housing ]
4 Tapered roller bearing inner race
• Pulling off --> [ Pulling Off Inner Race/Tapered Roller Bearing ]
• Pressing on --> [ Pressing On Inner Race/Tapered Roller Bearing ]
5 Differential housing
• With riveted final drive gear
6 Tapered roller bearing inner race
• Pulling off --> [ Pulling Off Inner Race/Tapered Roller Bearing ]
• Pressing on --> [ Pressing On Inner Race/Tapered Roller Bearing ]
7 Tapered roller bearing outer race
• Pulling out --> [ Pulling Outer Race/Tapered Roller Bearing Off Clutch Housing ]
• Pressing in --> [ Pressing Outer Race/Tapered Roller Bearing into Clutch Housing ]
8 Washer
• Installation position: Shoulder on inner diameter faces toward seal --> [ (item 13) Seal ]
9 Clutch housing
10 Countersunk bolt, 33 Nm
• Screw together with threaded piece --> [ 22 Threaded piece ]
11 Flange shaft, right
12 Protective ring
• Pry off protective ring from flange shaft on alternating sides using a screwdriver --> [ 11 Flange shaft, right ]
• Installation position: Depression points away from threaded holes in flanged shaft
• Press on protective ring by hand until stop
• Protective ring must engage with flanged shaft
13 Seal
• For right drive flange
• Replace with transmission installed --> [ Right Flange Shaft Seal ] Right Flange Shaft Seal
14 Spring for flanged shaft
• Installed behind flanged shaft
15 Thrust washer
• Installation position: Collar to compression spring, faces (if installed) to tapered ring
16 Tapered ring
• Installation position: Taper toward differential housing
17 Circlip
• Holds tapered ring, thrust washer and spring in position with flanged shaft removed
18 Large differential bevel gear
• Installing --> [ Installing Differential Planetary Gears ]
19 Differential planetary gear axle
• Driving out using drift
• Installing --> [ Installing Differential Planetary Gears ]
20 Roll pin
• For securing shaft for differential bevel gears
• Removing and installing --> [ Removing and Installing Roll Pin for Differential Bevel Gear Axle ]
21 Small differential bevel gear
• Installing --> [ Installing Differential Planetary Gears ]
22 Threaded piece
• Installing --> [ Installing Differential Planetary Gears ]
23 Thrust washer connection
• Install coated with gear oil
24 Protective ring
• Pry out protective ring using a screwdriver alternating --> [ 25 Flange shaft ]
• Installation position: Depression points away from threaded holes in flanged shaft
• Press on protective ring by hand until stop
• Protective ring must engage with flanged shaft
25 Flange shaft
26 Seal
• For left flanged shaft
• Replace with transmission installed --> [ Left Flange Shaft Oil Seal ] Left Flange Shaft Oil Seal.
Pulling Outer Race/Tapered Roller Bearing Off Clutch Housing
A Support, e.g. (Kukko 22/2)
B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)
• Replace shim after pulling out.
Pressing Outer Race/Tapered Roller Bearing into Clutch Housing
- Insert shim beforehand.
• Observe installed location of washer, shoulder on inner diameter faces toward seal.
Pulling Off Inner Race/Tapered Roller Bearing
- Before installing puller, set thrust piece (40 - 105) onto differential housing.
Pressing On Inner Race/Tapered Roller Bearing
Pulling Off Inner Race/Tapered Roller Bearing
A Extractor, e.g. (Kukko 18/1)
B Separating device 12 to 75 mm, e.g. (Kukko 17/1)
Pressing On Inner Race/Tapered Roller Bearing
Cage with tapered roller bearings must be able to be turned easily when pressing on.
Pulling Outer Race/Tapered Roller Bearing out of Transmission Housing
A Support, e.g. (Kukko 22/2)
B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)
Pressing In Tapered Roller Bearing Outer Race into Transmission Housing
- Support transmission housing directly beneath bearing mount using tube (3345).
Removing and Installing Roll Pin for Differential Bevel Gear Axle
Removing
- Cover inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.
- Drive out spring pin with chisel, inserting chisel into circumferential groove.
Installing
- Drive into differential housing until stop.
Installing Differential Planetary Gears
- Insert thrust washer connection with transmission oil before installing.
- Insert both large differential bevel gears and secure (e.g. with flange shaft).
- Install small differential bevel gears at 180° offset and pivot them into position.
- Press in differential bevel gear axle - arrow A - up to first small differential bevel gear.
- Insert threaded pieces - arrows B - into large differential bevel gears.
Installation position: Shoulder faces toward differential bevel gear
- Drive differential planetary gear axle into final position and secure with spring pin.