Torsen differential cover, removing and installing

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Special tools, testers and auxiliary items required

Fig 1: Seal Remover T40014

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Seal remover T40014

Fig 2: Pressure Stand T40099

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressure stand T40099
Ice spray
Protective gloves

Removing:

Input shaft removed → Input shaft, removing and installing .

Fig 3: Identifying Oil Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull oil pipe - arrow - upward and out to avoid damage.

Fig 4: Checking All 8 Screws On Pressure Stand T40099

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check all 8 screws - arrows - on Pressure Stand T40099.

Screws must be installed flush to 25 Nm Assembly instructions for pressure stand T40099.

Fig 5: Pulling Out Input Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert input shaft in pressure stand T40099.
Rotate seal ring extractor T40014 by hand into shaft seal until tool has a good hold in the shaft seal. Then tighten puller with an opened wrench.
You can pull out shaft seal a short distance by installing rear bolt - arrow -.
Re-tighten Seal ring extractor T40014 so that puller engages securely in shaft seal again and continue turning bolt to pull out shaft seal.

Repeat procedure until shaft seal has been pulled out completely.

Fig 6: Removing Input Shaft Cover Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove input shaft cover circlip - A -.
Measure and note thickness of removed circlip.

NOTE:

When installing, circlip must be replaced with a new circlip of same thickness.

Fig 7: Cleaning Cover Sealing Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clean cover sealing surface - arrow -.

CAUTION: Wear protective gloves!

The ice spray can reach temperatures under 0° Celsius which can freeze the skin without protective gloves.

Fig 8: Cooling Hollow Shaft On Inside Of Ball Bearing Seat Over Opening Of Removed Oil Pipe With Ice Spray

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cool hollow shaft - 1 - on inside of ball bearing - 2 - seat - arrow 2 - over opening - arrow 1 - of removed oil pipe with ice spray, for example.

NOTE:

Shaft represented in section here.
Shaft must be cooled so that ball bearing - 2 - can be pressed off more easily and not be damaged.

Fig 9: Inserting Input Shaft In Pressure Stand T40099

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clean surface of pressure stand T40099.
Insert input shaft in pressure stand T40099.

Input shaft sealing surface must be flush.
There must be no objects such as cable ties or dirt between input shaft sealing surfaces and surface of pressure stand T40099.

CAUTION: Shavings or dirt damage cover sealing surfaces when pressed, cover must then be replaced.

Also cool shaft from outside - arrow - with ice spray, for example.

NOTE:

Shaft must be cooled so that ball bearing can be pressed off more easily and not be damaged.

Place input shaft together with pressure stand T40099 on hydraulic press thrust plate.

NOTE:

Pressure stand T40099 should lie on as much surface of hydraulic press as possible.

Fig 10: Holding Shaft From Below And Pressing Shaft Out Of Cover With Hydraulic Press

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hold shaft from below and at the same time, press shaft out of cover with hydraulic press.

Fig 11: Placing Input Shaft On Assembly Tool T10219/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place input shaft on assembly tool T10219/1.

NOTE:

Ignore screwdriver and arrows.

Installing:

Replace ball bearing in input shaft cover → Ball bearing in input shaft cover, replacing

Fig 12: Placing Input Shaft Cover On Input Shaft And Pressing On By Hand As Far As Possible

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place input shaft cover on input shaft and press on by hand as far as possible.

Fig 13: Placing Input Shaft On Thrust Plate VW 401 & Pressing Input Shaft Cover With Tube VW 416 B Onto Input Shaft Up To Stop

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place input shaft - B - on Thrust plate VW 401.

CAUTION: Place input shaft straight and centered under hydraulic press thrust disc; otherwise input shaft can tip to the side when cover is pressed on.

With hydraulic press, press input shaft cover - A - with Tube VW 416 B onto input shaft up to stop.

Input shaft cover circlip, installing

Fig 14: Input Shaft Cover Circlip, Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When installing, circlip - A - must be replaced with a new circlip of same thickness.

NOTE:

Check for correct circlip seating.

Oil pipe, installing

Check wear on transmission components → Transmission components, evaluating wear

Fig 15: Identifying O-Ring, Oil Pipe & Rotor Blades

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace O-ring on oil pipe - 2 -.

The oil pipe is pressed into the input shaft with the O-ring - 2 -.
Oil pipe must engage noticeably, rotor blades - arrow A - on oil pipe must lie completely in input shaft.

Fig 16: Identifying Oil Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press oil pipe - arrow - down into input shaft to stop.

If oil pipe is inserted completely, the dimension from its end to the input shaft is approx. 11.5 mm.

If dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.

If dimension is larger, it is not pushed in far enough.

CAUTION:

Input shaft must not be set down on the projecting oil pipe - arrow - otherwise it will be damaged.
If the oil pipe is damaged, starting problems or a transmission malfunction will result.