Differential, disassembling and assembling: Notes
Special tools and equipment required
- VW 402 Thrust plate
- VW 408 A Press tool
- VW 411 Press tool
- 30-205 Thrust plate
- 40-21 Press tool
- V.A.G 1582 Tapered roller bearing puller
- VW 191
- VW 472/1 Thrust piece
- VW 472/2 Thrust piece
- VW 792 Thrust piece
- 3347 Assembly tool
- 2010
- VW 433 Thrust piece
- V.A.G 1582/6 Grip
- V.A.G 1582/6A Grip
- V.A.G 1582/11 Grip
- Kukko 21/7 Internal puller
- Kukko 22/2 Counter-support
- V.A.G 1582/3 Clamping ring
NOTE:
For transmissions produced from 04.98, the tool for removing the tapered roller bearings in the final drive and differential is VAG 1582/8
- 30-555 Thrust piece
NOTE:
- Heat tapered roller bearing inner race to 100 ° C before pressing on.
- Heat adjusting ring for tapered roller bearing to 100 ° C before pressing in tapered roller bearing outer race.
1 - Differential housing with riveted gear for final drive
- Final drive gear is riveted onto differential housing and then machined
- If differential or final drive gear is damaged, replace differential housing together with riveted final drive gear
- Number of teeth on final drive gear. Refer to Code letters, application, ratios, equipment
- Differential housings differ depending on diameter of tapered roller bearings
2 - Output shaft/drive flange
- Removing and installing. Refer to Differential, removing and installing
3 - Tapered roller bearing inner race
- There are different sizes of tapered roller bearings. Installed location can vary
- Pulling off. See Pulling off tapered roller bearing inner race and Pulling out tapered roller bearing outer race
- Pressing on. See Pressing on tapered roller bearing inner race (with equal sized bearings on both sides)
- Pressing on. See Pressing in tapered roller bearing outer race
4 - Tapered roller bearing outer race
- Remove and install only when adjusting ring is heated
- Drive out with drift
- Pressing in. See Pressing in tapered roller bearing outer race
5 - Bearing body for tapered roller bearing
- There are different types of bearing body
- Removing and installing. Refer to Removing and installing differential, Differential, removing and installing
- Pulling off tapered roller bearing/inner race. Refer to Pulling off tapered roller bearing inner race
- Pressing on. See Pressing in tapered roller bearing outer race
- Pressing on. See Pressing on tapered roller bearing inner race
6 - O-ring
- Always replace
7 - O-ring
- Always replace
8 - Adjusting ring for tapered roller bearing
- Removing and installing. Refer to Differential, removing and installing ; Differential, removing and installing
9 - Output shaft/drive flange
- Removing and installing. Refer to Differential, removing and installing ; Differential, removing and installing
10 - Tapered roller bearing outer race
- Remove and install only when adjusting ring is heated
- Drive out with drift
- Pressing in. See Pressing in tapered roller bearing outer race
11 - Tapered roller bearing inner race
- There are different sizes of tapered roller bearings. Installed location can vary
- Pulling off. Refer to Pulling off tapered roller bearing inner race (with equal sized bearings on both sides)
- Pressing on. See Pressing on tapered roller bearing inner race
- Inserting. See Inserting differential bevel gears
12 - Driver bushing
- Drive off together with speedometer drive gear item -13
- Drive on with drift
13 - Speedometer drive gear
- Drive out with a drift
- Fit on together with driver bushing item -12
14 - One-piece thrust washer
- Place into differential cage before inserting bevel gears
15 - Small bevel gears
16 - Large bevel gears
- Inserting. See Inserting differential bevel gears
17 - Circlip
WARNING:
Do not remove circlip until after pulling off drive flange as compression spring is pre-tensioned.
18 - Bevel gear shaft
- Drive out with a drift
- When driving in, do not damage one-piece thrust washer
19 - Spring pin
- For securing bevel gear shaft
- Removing and installing. See Removing and installing spring pin for bevel gear shaft