Inner Output Shaft, Disassembling And Assembling, Only Vehicles With Self-Locking Center Differential

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Special tools and workshop equipment required 

• Locking Pin Driver:30-505 
• Bearing Installer - Multiple Use:40-20 
• Press Plate:VW402 
• Press Piece - Multiple Use:VW412 
• Press Piece - Multiple Use:VW473 
• Bearing Installer - Wheel Bearing:3345 

Special tools and workshop equipment required 

• Valve Guide/Clutch Release Push Rod Seal Drift:10-206 

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• Piston Pin Drift:VW207 
  Fig 1: Identifying Bearing Installer

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• Socket - Xzn 18mm:T10162A 
  Fig 2: Socket XZN 18 T10162

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• Gearbox Assembly Tool:T40213A 
  Fig 3: Assembly Tool T40213

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• Extracting Tool - Adapter:T40413/7 
• Extracting Tool - Pin:T40413/9 

• Inner output shaft, removing. Refer to Inner Output Shaft Roller Bearing, Removing, Vehicles with Self-Locking Center Differential .

Disassembling

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-- Depending on the diameter -a- install the three Extracting Tool - Pin:T40413/9  -3- in the Extracting Tool - Adapter:T40413/7  -2- in the hole in the gear for the inner output shaft -1-.

• Dimension -a- = 62 mm threaded holes -A-
• Dimension -a- = 64 mm threaded holes -B-

-- Bolt the Extracting Tool - Adapter:T40413/7  with the Gearbox Assembly Tool:T40213A  .

-- Tighten the Gearbox Assembly Tool:T40213A  in the vise or on the Gearbox Support:T40206  .

-- Position the inner output shaft -1- on the Extracting Tool - Adapter:T40413/7  -3-.

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-- Warm the bolt -arrow- to approximately 100 °C (212 °F).

-- Remove the bolt -arrow- with the Socket - Xzn 18mm:T10162A  -2- from the inner output shaft -1-.

TIP:

• The bolt from the output shaft has a very high loosening torque.

If when warning the bolt the oil pipe -3- in the inner output shaft is damaged it must be replaced.

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-- Drive out the oil pipe -3- using the Valve Guide/Clutch Release Push Rod Seal Drift:10-206  -2- and Piston Pin Drift:VW207  -1- in -direction of the arrow- out of the inner output shaft.

-- Drive in the new oil pipe on the opposite side again.

Inner output shaft 1, pressing out

Fig 4: Inner Output Shaft -1-, Pressing Out

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2 -  Press Piece - Multiple Use:VW412 

3 -  Locking Pin Driver:30-505 

4 -  Press Plate:VW402 

• All additional components remaining on the Press Plate:VW402  must be secured from falling.

-- When removing the components in the sequence, at the same time pay attention to the installation position. Refer to OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL .

Roller bearing 1 from the bearing shell 2, pressing out

Fig 5: Roller Bearing -1- from the Bearing Shell -2-, Pressing Out

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3 -  Press Piece - Multiple Use:VW473 

4 -  Bearing Installer - Wheel Bearing:3345 

5 -  Press Plate:VW402 

• Remove the locking ring  OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL beforehand.

Assembling

Drive wheel for spur gear unit 1, pressing on

Fig 6: Drive Wheel for Spur Gear -1-, Pressing On

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2 -  Press Plate:VW402 

3 -  Bearing Installer - Multiple Use:40-20 

• Installation position: the groove -arrow- from the drive wheel for spur gear unit -1- points to the Bearing Installer - Multiple Use:40-20  .

Ball bearing 1, pressing on

Fig 7: Ball Bearing -1-, Pressing On

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3 -  Press Plate:VW402 

4 -  Bearing Installer - Multiple Use:40-20 

• Installation position: the shoulder -arrow- points to the drive wheel for spur gear unit -2-.

-- Depending on the diameter -a- install the three Extracting Tool - Pin:T40413/9  -3- in the Extracting Tool - Adapter:T40413/7  -2- in the hole in the gear for the inner output shaft -1-.

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• Dimension -a- = 62 mm threaded holes -A-
• Dimension -a- = 64 mm threaded holes -B-

-- Bolt the Extracting Tool - Adapter:T40413/7  with the Gearbox Assembly Tool:T40213A  .

-- Tighten the Gearbox Assembly Tool:T40213A  in the vise or on the Gearbox Support:T40206  .

-- Position the inner output shaft -1- on the Extracting Tool - Adapter:T40413/7  -3-.

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-- Clean the internal threads of the inner output shaft with a thread tap.

-- Install the new bolt -arrow- using the Socket - Xzn 18mm:T10162A  -2- and tighten.

Roller bearing 1 in the bearing shell 2, pressing in

Fig 8: Roller bearing -1- in the Bearing Shell -2-, Pressing in

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3 -  Press Piece - Multiple Use:VW473 

4 -  Bearing Installer - Wheel Bearing:3345 

5 -  Press Plate:VW402 

• Position the roller bearing -1- with the lettered side (larger panel thickness) to the Press Piece - Multiple Use:VW473  -3-.

-- Install the circlip  OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL.

Tightening Specifications

• Refer to OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL