Final Drive Assembly: Disassembly

NOTE: Backlash and turning torque should be measured and recorded before final drive disassembly. If parts are used again, set backlash and turning torque to same values as measured. See PINION SHAFT TURNING TORQUE and PINION DEPTH & BEARING PRELOAD for measuring instructions.

Place final drive housing in holding fixture. Mark position of side bearing adjusting rings before removing. Remove governor assembly from final drive housing. See Fig 1 . Use slide hammer to remove governor oil seal and needle bearing.
Remove ATF oil cooler from case. Remove final drive housing front cover. Remove pinion rear cover. Remove retaining bolt from center of each axle drive flange. Pull flanged shafts out of final drive housing.
Remove bolts and lock plates from adjusting rings. Remove adjusting rings using Spanner (VW 544). Pull pinion out slightly. Tilt differential case and remove ring gear. Remove pinion shaft from housing.
Place differential case assembly in soft jaw vise with ring gear attaching bolts up. Loosen attaching bolts and remove ring gear by tapping lightly on bolt heads.

Fig 1: Exploded View Of Typical Final Drive Assembly
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove pinion gears, side gears, thrust washers and nuts for axle shaft drive flange retaining bolts. See Fig 2 . Remove differential side bearings and speedometer drive gear (if equipped) with press or gear puller. Mark side bearings for installation reference.
CAUTION: If original shims are to be reused, note number and thickness of pinion adjusting shims on pinion shaft. When pressing drive pinion bearings on or off, use extreme care to avoid damage to any teeth on shaft.
Remove drive pinion bearings using press. Remove rear pinion bearing and oil sleeve. Pinion bearing outer races and oil seals must be replaced if pinion bearings are replaced. Remove torque converter seal from front cover. Remove front cover pinion seal.
Press pinion bearing outer race from front cover. Remove pinion oil seals from rear cover. Press pinion bearing outer race from rear cover using driver.

Fig 2: Exploded View Of Differential Case Assembly (087 Model)

NOTE: If pinion bearing outer races are being removed, ensure races are kept with their original bearings.