Differential, Disassembling And Assembling

Special tools and workshop equipment required 

• Seal Installer - Crankshaft VW204B
• Bearing/Bushing Installer - Multiple Use VW295
• Press Plate VW402
• Press Piece - Multiple Use VW412
• Press Piece - Rod VW408A
• Puller - Grease Cap VW637/2
• Bearing Installer - Needle Bearing 30-506B
• Press Piece - Multiple Use 40-105
• Press Piece - Ring 2006A
• Press Piece - Multiple Use 3005
• Bearing Installer - Wheel Bearing 3345
• Pressure Sleeve T10299
• Puller - Kukko Internal 21/89
• Puller - Roller Bearing VAS6775
• Puller - Kukko Counterstay 22/2
• Puller - Kukko Counterstay 22/4
• Press Piece - Multiple Use VW447H
• Puller - Taper Roller Bearing VAG1582
• Puller - Taper Roller Bearing - Adapter 8 VAG1582/8
• Puller - Taper Roller Bearing - Adapter 15 VAG1582/15
• Inductive Heater VAS6414

-- Secure the transmission to the transmission holder and drain the transmission fluid. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

Fig 1: Securing T40206 To Transmission With Bolts And Tighten It In Assembly Stand

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-- Remove the clutch module. Refer to CLUTCH MODULE, REMOVING AND INSTALLING .

Fig 2: Removing/Installing Flywheel Components

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-- Remove the differential. Refer to DIFFERENTIAL, REMOVING AND INSTALLING .

Fig 3: Identifying Differential

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Fig 4: Removing Left Tapered Roller Bearing Outer Race -B- From The Transmission Housing

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A - Counter Support, for example, Puller - Kukko Counterstay 22/2

To remove, place the Puller - Roller Bearing VAS6775 under the outer race -B-.

-- Check the shim for damage after removing.

Fig 5: Driving Outer Race For Tapered Roller Bearing With Shim Into Transmission Housing

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Fig 6: Pulling Off Inner Race For Tapered Roller Bearing (Right-Side)

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-- Mount the Press Piece - Multiple Use 40-105 on the differential housing before removing the puller.

Fig 7: Removing Left Tapered Bearing Inner Race (Efficiency Bearing)

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-- Mount the Press Piece - Multiple Use 40-105 on the differential housing before removing the puller.

Fig 8: Installing Left Tapered Bearing Inner Race (Normal And Efficiency Bearing)

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-- Heat inner race to approximately 100 °C, fit in position and press in.

Fig 9: Removing Right Tapered Bearing Inner Race (Standard Bearing)

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-- Carefully clamp the differential in a vise with the protective jaws -A-.

-- Before installing the puller, set Press Piece - Multiple Use VW447H onto differential housing.

Fig 10: Removing Right Angular Contact Ball Bearing Inner Race (Efficiency Bearing)

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-- Carefully clamp the differential in a vise with the protective jaws -A-.

-- Remove bearing cage with ball bearings from the inner race.

-- Before installing the puller, set Press Piece - Multiple Use VW447H onto differential housing.

Fig 11: Pressing On The Right Tapered Bearing Inner Race Or The Angular Contact Ball Bearing Inner Race

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-- Heat inner race to approximately 100 °C, fit in position and press in.

Fig 12: Removing Outer Race Tapered Bearing

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A - Counter Support, for example, Puller - Kukko Counterstay 22/4

B - Internal Puller 56 to 110 mm, for example, Puller - Kukko Internal 21/89

Fig 13: Installing Outer Race Tapered Bearing

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-- Install the shim in the final drive cover.

-- Press the outer race/tapered roller bearing in all the way. The smaller diameter of the Seal Installer - Crankshaft VW204B faces the outer race.

Fig 14: Prying Outer Race Tapered Bearing

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-- First press the angular contact ball bearing outer race slightly out of the bearing seat by installing the Puller - Grease Cap VW637/2 continuously in small steps and press in the -direction of the arrow-.

-- Then pull out the outer race using the Puller - Kukko Internal 21/89 -B- and the Puller - Kukko Counterstay 22/4 -A-

Fig 15: Removing Outer Race Tapered Bearing

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A - Counter Support, for example, Puller - Kukko Counterstay 22/4

B - Internal Puller 56 to 110 mm, for example, Puller - Kukko Internal 21/89

Fig 16: Installing Outer Race Tapered Bearing

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-- Install the shim in the final drive cover.

-- Press the angular contact ball bearing outer race in all the way. The larger diameter of the Seal Installer - Crankshaft VW204B faces the outer race.