Differential, disassembling and assembling: Notes

WARNING: This page is about a different variant/trim than selected.

Fig 1: Identifying Special Tools - Differential, Disassembling And Assembling (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The following special tools and testing devices are required:

Thrust plate VW 401
Thrust plate VW 402
Punch VW 407
Thrust disc VW 412

Needle bearing drift VW 295
Punch VW 408 A

Fig 2: Identifying Special Tools - Differential, Disassembling And Assembling (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thrust pad VW 442
Sleeve 40-21
Thrust piece 40-105
Thrust plate 2050

Drift 3138
Two-arm puller Kukko 44/2

Fig 3: Tapered Roller Bearing Puller V.A.G 1582

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Taper roller bearing extractor V.A.G 1582

Fig 4: Tapered Roller Bearing Puller V.A.G 1582

Courtesy of VOLKSWAGEN UNITED STATES, INC.

V.A.G 1582/6

NOTE:

Fig 5: Rear Differential, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

General repair instructions. Refer to Repair instructions .
Secure final drive on a repair stand. Refer to Secure complete rear final drive on a repair stand with bracket VW 540 .
Replace both taper roller bearings together.
When replacing the parts marked with 1) adjustment work is required. Refer to Adjustment overview .

1 - Cover for final drive 1)

2 - O-ring

Replace
Insert with oil

3 - Final drive housing 1)

4 - Shim "S1"

Note thickness
Adjustment overview. Refer to Adjustment overview .

5 - Outer race for small taper roller bearing 1)

Tapping out. See Figure
Pressing in. See Figure

6 - Inner race for small taper roller bearing 1)

Pulling off. See Figure
Pressing on. See Figure

7 - Bolt - 60 Nm plus an additional45°1/4 turn

Replace
Allocation

Lightly tighten bolts then tighten diagonally to specified torque.

8 - Differential housing 1)

9 - Ring gear 1)

Paired with pinion shaft (final drive set)
Allocation based on transmission code letters

Drive off housing with a drift. See Figure
Install to differential housing. See Figure

10 - Spring pin

For securing shaft for bevel gears
Drive in flush

11 - Inner race for large taper roller bearing 1)

Pulling off. See Figure
Pressing on. See Figure

12 - Outer race for large taper roller bearing 1)

Tapping out. See Figure
Pressing in. See Figure

13 - Shim "S2"

Note thickness
Adjustment overview. Refer to Adjustment overview .

14 - Threaded piece

15 - Large bevel gear

Installing. See Figure
Adjusting. See Figure

16 - Small bevel gear

Installing. See Figure

17 - Shaft for planet wheels

Drive out with drift

18 - Adjustment shim

Redefine thickness. See Figure

19 - Thrust washer

Check for cracks