Differential, disassembling and assembling: Notes
WARNING: This page does not describe the selected car, but rather 21 other vehicles, including the 2002 Volkswagen Cabrio, 2001 Volkswagen Cabrio, 2000 Volkswagen Cabrio, 1999 Volkswagen Jetta, and 1999 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
The inner and outer races of the tapered roller bearings are a matched set and cannot be interchanged.
The following list pertains to Fig 1.
- Final drive gear
- Matched to output shaft
- Pressing off, see Pressing off final drive gear
- Installing, see Installing final drive gear
- If gear set is replaced, adjust output shaft. See OUTPUT SHAFT, ADJUSTING .
- Special rivet
- Removing, see Sawing off special rivets for removal of differential pinion gears
- Secures shaft for differential gears
- When repairing differential, secure shaft with circlips
- Tapered roller bearing inner race, opposite final drive gear
- Removing, see Removing tapered roller bearing inner race
- Installing, see Pressing on inner race of tapered roller bearing for differential housing
- First remove drive flange output shafts -10-
- When replacing: adjust differential, see DIFFERENTIAL, ADJUSTING
- Tapered roller bearing outer race
- Remove sleeve -8- before removing
- Removing, see Driving tapered roller bearing outer race out of clutch housing
- Installing, see Driving tapered roller bearing outer race into clutch housing
- Shim S2
- Always 1 mm thick
- Securing set
- For attaching final drive gear to differential housing
- For service only
- Original production parts item --
- Installing, see Attaching final drive gear to differential housing
- Hex nut tightening torque: 65 N.m (48 ft lb)
- Clutch housing
- Sleeve
- Removing and installing, see CLUTCH HOUSING, SERVICING
- Oil seal
- Removing and installing, see DRIVE FLANGE OIL SEALS, REMOVING AND INSTALLING
- Drive flange output shaft
- Remove circlip -23- before removing
- Turn lightly during removal
- Press in carefully during installation
- Threaded socket is opposite differential bearings
- Do not damage thrust washer
- Tapered roller bearing inner race, final drive gear side
- Removing, see Removing tapered roller bearing inner race
- Installing, see Pressing on inner race of tapered roller bearing for differential housing
- First remove drive flange output shafts -10-
- When replacing: adjust differential, see DIFFERENTIAL, ADJUSTING
- Tapered roller bearing outer race
- Shim S1
- Determining size, see DETERMINING THICKNESS OF SHIM S1
- Transmission housing
- Servicing, see TRANSMISSION HOUSING, SERVICING
- Circlip
- Always replace
- Must seat securely in groove
- Dished washer
- Drive flange
- Removing and installing, see DRIVE FLANGE OIL SEALS, REMOVING AND INSTALLING
- Spring
- Thrust washer
- Tapered ring
- Differential housing
- When replacing: adjust differential, see DIFFERENTIAL, ADJUSTING
- One-piece thrust washer
- Lubricate with gear oil before installation
- Circlip
- Secures drive flange output shaft -10-
- Shaft for differential gears
- Removing, see Sawing off special rivets for removal of differential pinion gears
- Drive out using drift
- Do not damage one-piece thrust washer when installing
- For repairs use shaft with grooves and secure with circlips
- Circlip
- Differential gears
- Removing, see Sawing off special rivets for removal of differential pinion gears
- Installing, see Installing differential pinion gears
- Rivet
- For attaching final drive gear to differential housing
- For production only
- For repairs, use securing set -6-
- Drilling out, see Drilling out rivet heads
- Cover
- Destroyed by removal, see DRIVE FLANGE OIL SEALS, REMOVING AND INSTALLING