Differential, Disassembling And Assembling

Courtesy of AUDI

Special tools and workshop equipment required 

• Seal Installer - Crankshaft:VW 204 B 
• Bearing/Bushing Installer - Multiple Use:VW 295 
• Press Plate:VW 401 
• Press Plate:VW 402 
• Press Piece - Multiple Use:VW 412 
• Press Piece - Multiple Use:VW 447 H 

Courtesy of AUDI

Special tools and workshop equipment required 

• Bearing Installer - Needle Bearing:30 - 506 B 
• Press Piece - Multiple Use:40 - 105 
• Press Piece - Multiple Use:3005 
• Bearing Installer - Wheel Bearing:3144 
• Press Piece - Reverse Gear Syncro:3296 
• Bearing Installer - Wheel Bearing:3345 

Special tools and workshop equipment required 

• Puller - Grease Cap:VW 637/2 
  Fig 1: Identifying Puller - Grease Cap VW637/2

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• Thrust Sleeve:T10299 
  Fig 2: Pressure Sleeve T10299

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• Puller - Taper Roller Bearing:V.A.G 1582 

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• Puller - Taper Roller Bearing - Adapter 16A:V.A.G 1582/16A 
• Puller - Taper Roller Bearing - Adapter 17:V.A.G 1582/17 
• Inductive Heater:VAS 6414 
  Fig 3: Identifying Heater

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• -4- Internal Puller (Kukko 21/89):VAS 251 619 
  Fig 4: Identifying Kukko Puller

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• -4- Puller - Roller Bearing (Kukko 21-8):VAS 6775 
• -3- Counter Support:VAS 251 623 
• -1- Counter Support (Kukko 22/4):VAS 251 625 

Before performing assembly work on the differential, drain the transmission fluid, secure the transmission on the assembly stand, and remove the flywheel with the right flange shaft. Refer to FLYWHEEL, REMOVING AND INSTALLING .

-- Secure the transmission on the transmission holder. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

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

Left Tapered Roller Bearing Outer Race, Removing from Transmission Housing

Fig 5: Left Tapered Roller Bearing Outer Race, Removing from Transmission Housing

Courtesy of AUDI

1. Counter Support:VAS 251 623 
2. Puller - Roller Bearing (Kukko 21-8):VAS 6775 

Use the Puller - Roller Bearing:VAS 6775  so that it can be positioned under the outer race.

-- Check the shim for damage after removing.

Left tapered roller bearing outer race, driving into transmission housing

Fig 6: Driving Outer Race For Tapered Roller Bearing With Shim Into Transmission Housing

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• Install the shim in the transmission housing.

Removing the left tapered roller bearing inner race

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

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-- Before installing the puller, mount the Press Piece - Multiple Use:40-105  onto the differential housing.

Left Tapered Roller Bearing Inner Race, Installing

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

Courtesy of AUDI

TIP:

• Wear safety gloves.

-- Support the differential on the bottom using the Bearing Installer - Needle Bearing:30 - 506 B  . Do not place on the inner race.

-- Warn the inner race using the Inductive Heater:VAS 6414  to 100 °C (212 °F) and press it in.

Right Angular Contact Ball Bearing Inner Race, Removing

Fig 9: Removing Right Angular Contact Ball Bearing Inner Race (Efficiency Bearing)

Courtesy of AUDI

-- 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 the Press Piece - Multiple Use:VW 447 H  onto the differential housing.

Right Angular Contact Ball Bearing Inner Race, Installing

Fig 10: Press on the right tapered bearing inner race or the angular contact ball bearing inner race.

Courtesy of AUDI

-- Support the differential on the bottom using the Bearing Installer - Needle Bearing:30 - 506 B  . Do not place on the inner race.

TIP:

• A tapered roller bearing inner race is shown. Installing the angular contact ball bearing inner race is identical.

-- Heat inner race to approximately 100 °C (212 °F), fit in position and press in.

Angular Contact Ball Bearing Outer Race, Loosening Slightly from Bearing Seat

Fig 11: Prying Outer Race Tapered Bearing

Courtesy of AUDI

TIP:

• Warm the final drive cover to approximately 100 °C (212 °F) with the Hot Air Blower so that the outer race for the angular contact ball bearing can be more easily removed.

-- Then press the angular contact ball bearing outer race slightly out of the bearing seat by gradually installing the Puller - Grease Cap:VW 637/2  in small steps and pressing in the -direction of the arrow-.

-- Then remove the angular contact ball bearing outer race from the final drive cover. Refer to Fig 12.

Angular Contact Ball Bearing Outer Race 3, Removing from Final Drive Cover

Fig 12: Angular Contact Ball Bearing Outer Race -3-, Removing from Final Drive Cover

Courtesy of AUDI

1. Counter Support (Kukko 22/4):VAS 251 625 
2. Internal Puller (Kukko 21/89):VAS 251 619 

Installing the angular contact ball bearing outer race into the final drive cover

Fig 13: Identifying Outer Race Tapered Bearing, Installation

Courtesy of AUDI

-- 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:VW 204 B  faces the outer race.

-- Support the final drive cover by supporting the Bearing Installer - Wheel Bearing:3345  directly under the bearing mount.