Differential, disassembling and assembling: Assembling

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.

Lubricate one-piece thrust washer with transmission fluid before installing.
Insert both large differential bevel gears and secure (e.g. with flanged shaft).

Fig 1: Rotating Flanged Shafts

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Insert small differential bevel gears at 180 ° offset and swing in by rotating on one of two flanged shafts.
Drive in differential bevel gear axle to final position and secure with roll pin.

Fig 2: Pressing Ball Bearing Into Cover Using Special Tools

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Press ball bearing into cover.
Secure with large circlip.

Fig 3: Pressing Cover On Differential Using Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press cover on differential.
Secure with small circlip.
Drive in new seal flush. → Seals for flanged shafts on rear final drive, replacing