Differential, disassembling and assembling: Notes

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools -- Differential, Disassembling And Assembling (1 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine support adapter VW 353
Pressure plate VW 401
Pressure plate VW 402
Punch VW 407

Punch VW 408A
Punch VW 412

Special tools, testers and auxiliary items required

Fig 2: Identifying Special Tools -- Differential, Disassembling And Assembling (2 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thrust piece V.A.G 40-105
Thrust piece VAS 3005
Line VAS 3259
Line VAS 3296

Tube for wheel bearing VAS 3345
Torque wrench V.A.G 1332

Special tools, testers and auxiliary items required

Fig 3: Identifying Special Tools -- Differential, Disassembling And Assembling (3 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tapered roller bearing puller V.A.G 1582
Attachment V.A.G 1582/6
Internal puller 1 Kukko 21/7
Extractor 2 - Kukko 18/1

Separating device 3 - Kukko 17/1
Support 4 - Kukko 22/2

NOTE:

Heat inner race/tapered roller bearing to 100 ° C before installing.
Replace both tapered roller bearings together.
Adjust differential → Differential, adjusting when replacing tapered roller bearing, differential housing, transmission housing and clutch housing.

Fig 4: Exploded View Of Differential Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Transmission housing

2 - Bolt

3 - Differential housing

4 - Gear wheel for final drive

5 - Washer plate

6 - Nut, 40 Nm plus 45 ° (1/8 turn)

Always replace

7 - Clutch housing

8 - Adjustment shim

For differential
Determining thickness → Differential, adjusting

9 - Tapered roller bearing outer race

Pulling out: Pulling outer race/tapered roller bearing off clutch housing
Pressing in: Pressing outer race/tapered roller bearing into transmission housing

10 - Inner race/tapered roller bearing

Pulling off: Pulling off inner races/tapered roller bearing
Pressing on: Pressing on inner races/tapered roller bearing

11 - Differential housing

12 - Inner race/tapered roller bearing

Pulling off: Pulling off inner races/tapered roller bearing
Pressing on: Pressing on inner races/tapered roller bearing

13 - Tapered roller bearing outer race

Pulling out: Pulling outer race/tapered roller bearing off clutch housing
Pressing in: Pressing outer race/tapered roller bearing into clutch housing

14 - Washer

Always 0.65 mm thick

15 - Connecting sleeve to bevel gear transfer case

Pressed onto differential housing
Pull off and press on only with differential housing removed
Pulling off: Pull off connecting sleeve - A -
Pressing on: Pressing on connecting sleeve - A - for bevel gear transfer case

16 - Seal

For right flanged shaft
Diameter is different on left and right sides
Replace with transmission installed → Right flanged shaft seal, replacing

17 - Bevel gear transfer case

Removing and installing with transmission installed → Bevel gear transfer case, removing and installing
Removing and installing with transmission removed

18 - Hex bolt, 40 Nm plus 45 ° (1/8 turn)

Always replace

19 - Washer

20 - Conical head bolt, 25 Nm

21 - Right flanged shaft

22 - O-ring

Always replace

23 - O-ring

Always replace

24 - O-ring

Always replace

25 - Large differential bevel gear

Installing: Installing small differential bevel gears
Allocate via Electronic Parts Catalog (ETKA)

26 - Differential bevel gear axle

Drive out using drift
Installing: Installing small differential bevel gears
Allocate via Electronic Parts Catalog (ETKA)

27 - Roll pin

For securing shaft for differential bevel gears
Allocate via Electronic Parts Catalog (ETKA)
Removing and installing: Removing and installing roll pin for differential bevel gear axle

28 - Small differential bevel gear

Installing: Installing small differential bevel gears
Allocate via Electronic Parts Catalog (ETKA)

29 - Threaded piece

Installing: Installing small differential bevel gears
Allocate via Electronic Parts Catalog (ETKA)

30 - Thrust washer connection

Lubricate with transmission fluid before installing

According to Electronic Parts Catalog (ETKA)

31 - Circlip

Holds tapered ring, thrust washer and compression spring in position with flanged shaft removed

32 - Tapered ring

With grooves for thrust washer to engage
Installed position: cone to differential housing

33 - Thrust washer

Installed position: Collar to compression spring, braces to tapered ring

34 - Compression spring for flanged shaft

Rear flanged shaft installed

35 - Left flanged shaft

With protective ring, as of transmission manufacture date 19053
Protective ring protects seal against soiling
Use screwdriver to pry out, alternating sides
Installed position: Depression points away from threaded holes in flanged shaft

Press on protective ring up to stop by hand
Protective ring must engage with flanged shaft

36 - Seal

For left flanged shaft
Diameter is different on left and right sides
Replace with transmission installed → Left flanged shaft seal, replacing