Differential, disassembling and assembling: Notes

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Special tools and equipment required

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VW 402 Thrust plate
VW 408 A Press tool
VW 411 Press tool
30-205 Thrust plate

40-21 Press tool
V.A.G 1582 Tapered roller bearing puller

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VW 191
VW 472/1 Thrust piece
VW 472/2 Thrust piece
VW 792 Thrust piece

3347 Assembly tool
2010

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VW 433 Thrust piece
V.A.G 1582/6 Grip
V.A.G 1582/6A Grip
V.A.G 1582/11 Grip

Kukko 21/7 Internal puller
Kukko 22/2 Counter-support

V.A.G 1582/3 Clamping ring

Fig 4: V.A.G 1582/3 Clamping Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: For transmissions produced from 04.98, the tool for removing the tapered roller bearings in the final drive and differential is VAG 1582/8

30-555 Thrust piece

Fig 5: 30-555 Thrust Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Heat tapered roller bearing inner race to 100 ° C before pressing on.
Heat adjusting ring for tapered roller bearing to 100 ° C before pressing in tapered roller bearing outer race.

Fig 6: Exploded View Of Differential Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Differential housing with riveted gear for final drive

Final drive gear is riveted onto differential housing and then machined
If differential or final drive gear is damaged, replace differential housing together with riveted final drive gear
Number of teeth on final drive gear. Refer to Code letters, application, ratios, equipment
Differential housings differ depending on diameter of tapered roller bearings

2 - Output shaft/drive flange

Removing and installing. Refer to Differential, removing and installing

3 - Tapered roller bearing inner race

There are different sizes of tapered roller bearings. Installed location can vary
Pulling off. See Pulling off tapered roller bearing inner race and Pulling out tapered roller bearing outer race
Pressing on. See Pressing on tapered roller bearing inner race (with equal sized bearings on both sides)
Pressing on. See Pressing in tapered roller bearing outer race

4 - Tapered roller bearing outer race

Remove and install only when adjusting ring is heated
Drive out with drift
Pressing in. See Pressing in tapered roller bearing outer race

5 - Bearing body for tapered roller bearing

There are different types of bearing body
Removing and installing. Refer to Removing and installing differential, Differential, removing and installing
Pulling off tapered roller bearing/inner race. Refer to Pulling off tapered roller bearing inner race
Pressing on. See Pressing in tapered roller bearing outer race

Pressing on. See Pressing on tapered roller bearing inner race

6 - O-ring

Always replace

7 - O-ring

Always replace

8 - Adjusting ring for tapered roller bearing

Removing and installing. Refer to Differential, removing and installing ; Differential, removing and installing

9 - Output shaft/drive flange

Removing and installing. Refer to Differential, removing and installing ; Differential, removing and installing

10 - Tapered roller bearing outer race

Remove and install only when adjusting ring is heated
Drive out with drift
Pressing in. See Pressing in tapered roller bearing outer race

11 - Tapered roller bearing inner race

There are different sizes of tapered roller bearings. Installed location can vary
Pulling off. Refer to Pulling off tapered roller bearing inner race (with equal sized bearings on both sides)
Pressing on. See Pressing on tapered roller bearing inner race
Inserting. See Inserting differential bevel gears

12 - Driver bushing

Drive off together with speedometer drive gear item -13
Drive on with drift

13 - Speedometer drive gear

Drive out with a drift
Fit on together with driver bushing item -12

14 - One-piece thrust washer

Place into differential cage before inserting bevel gears

15 - Small bevel gears

16 - Large bevel gears

Inserting. See Inserting differential bevel gears

17 - Circlip

WARNING:

Do not remove circlip until after pulling off drive flange as compression spring is pre-tensioned.

18 - Bevel gear shaft

Drive out with a drift
When driving in, do not damage one-piece thrust washer

19 - Spring pin

For securing bevel gear shaft
Removing and installing. See Removing and installing spring pin for bevel gear shaft