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 Tool (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) or equivalent

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)

• Replace the washer (- item 8 - in the => [ Differential Overview ] Description and Operation) after removing it.

Pressing the outer race/tapered roller bearing with washer into clutch housing.





- Install the old washer - item 8 - in the => [ Differential Overview ] Description and Operation) into the clutch housing.

• Pay attention to the washer installed position.

• The collar on the inner circumference faces the seal.

Removing the bearing inner race/taper roller bearing





- Before installing the puller, mount the thrust piece (40-105) onto the differential housing.

Installing the bearing inner race/taper roller bearing





The cage wit the tapered rollers must rotate easily when being installed.

Removing the bearing inner race/taper roller bearing





A Puler, 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 bearing inner race/taper 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 tool (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 chisel.

Installing

- Drive the roll pin 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: 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.