Disassembling And Assembling The Differential (Transmission G 86): Tools

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Fig 1: Identifying Special Tools

Courtesy of PORSCHE OF NORTH AMERICA, INC.

SPECIAL TOOLS

Item

Designation

Special tool

A⁽¹⁾

Pressure piece

VW 472/1

B⁽¹⁾

Pressure piece

P263

C⁽¹⁾

Pressure disc

VW 511

D⁽¹⁾

Pressure piece

2050

E⁽¹⁾

Drive-in mandrel

VW 295

⁽¹⁾

Fig 1 .

Fig 2: Exploded View Of Differential Assembly (Transmission G 86)

Courtesy of PORSCHE OF NORTH AMERICA, INC.

DIFFERENTIAL COMPONENT DESCRIPTION CHART (TRANSMISSION G 86)

No.

Designation

Qty.

Removal

Installation

Speedometer-drive gear

1⁽²⁾

2⁽²⁾

Tapered roller bearing inner race ⁽¹⁾

Remove with commercially available two-arm puller and special tool P 263

Heat to approx. 100°C, put into position and press again after heat exchange

3⁽²⁾

Tapered roller bearing inner race ⁽¹⁾

Same as No. 2

4⁽²⁾

Crown wheel screw

Always replace. The thread must be dry and grease-free. Tighten crosswise with 60 Nm (44 ft.lb) and then continue turning with a rotational angle of 45°C.

5⁽²⁾

Crown wheel ⁽¹⁾

Force off with a mandrel through the threaded holes

If required, heat up to approx. 100°C

6⁽²⁾

Dowel pin

Drive in the correct position

7⁽²⁾

Axle

8⁽²⁾

Differential bevel gear (small)

9⁽²⁾

Differential bevel gear (large)

10⁽²⁾

Thrust washer assembly

Insert with gear oil

11⁽²⁾

Differential housing ⁽¹⁾

12⁽²⁾

Tapered roller bearing outer race

Drive out using a suitable aluminum or copper mandrel (phi 6...8 mm)

Press in with special tools VW 511 (or 2050) and VW 295

13⁽²⁾

Adjusting shim "S1"

Note the thickness for installation

Remeasure the thickness if necessary

14⁽²⁾

Cover for final drive ⁽¹⁾

Seal with Loctite 574

15⁽²⁾

Tapered roller bearing outer race

Same as No. 12

Drive in with special tool VW 472/1

16⁽²⁾

Adjusting shim "S2"

Same as No. 13

17⁽²⁾

Transmission housing ⁽¹⁾

⁽¹⁾	If the parts are replaced, readjustment is necessary

⁽²⁾	For explanation see Fig 2