Torsen housing, disassembling and assembling: Notes

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required 

• Thrust plate VW401
• Thrust plate VW402
• Punch VW408A
• Thrust disc VW412

• Thrust tube VW454
• Arbor thrust piece VW554

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required 

• Punch 2005
• Thrust piece 2050
• Drift sleeve 30 - 100
• Torque wrench V.A.G 1331

• Shim 016311391A 
• Locking fluid AMV 185 101 A1 
• Sealing grease G 052 128 A1 

Fig 3: Torsen Housing Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Flange shaft

• Without vibration damper
• Pressing out Pressing out flange shaft 
• Pressing in Pressing in flange shaft 

2 - Needle bearing

• Pull out of flange shaft using internal puller Kukko 21/1 and counter-support Kukko 22/1.
• Press into flange shaft as far as it will go using punch VW 408 A.

3 - Bolt - 15 Nm plus an additional 90°¹ /₄ turn

• For vibration damper
• 3x
• Apply locking fluid AMV 185 101 A1  when installing

4 - Vibration damper

• Not installed on all versions
• Select correct version according to color coding - arrow  - or transmission code

5 - Oil seal

• Prying out Prying off oil seal. 
• Preparing for installation Preparing oil seal for installation 
• Driving in Drive in seal onto stop. 

6 - Torsen housing

• Removing and installing (transmission removed) → Disassembling and assembling sequence 
• Removing and installing (transmission installed) → Torsen housing, removing and installing (with transmission installed) 

7 - Oil collector

• Insert in hole on transmission cover

8 - Circlip

• For flange shaft
• Installation position Installation position of circlips - A - and - B - 

9 - Circlip

• For ball bearing and sleeve
• Installation position Installation position of circlips - A - and - B - 

10 - Sleeve

11 - Ball bearing

• For flange shaft
• Pressing out Pressing out ball bearing for flange shaft 
• Pressing in Pressing in ball bearing for flange shaft 

12 - Flange shaft with vibration damper

• Only replace as complete unit
• Pressing out Pressing out flange shaft 
• Pressing in Pressing in flange shaft