Disassembly And Assembly: Differential

Special Tools And Workshop Equipment Required 

• Thrust Plate VW 402
• Punch VW 408 A
• Thrust Disc VW 412
• Tube 60 mm Dia. VW 415 A
• Thrust Piece 40-105
• Thrust Pad 3005
• Tube 3259
• Tube 3296
• Press Tube 3345
• Tapered Roller Bearing Puller V.A.G 1582
• Attachment to VAG 1582 V.A.G 1582/6A
• Kukko Extractor 46-58 mm 21/7
• Kukko Puller 65-160 mm 18/1
• Kukko Separating Tool 12-75 mm 17/1
• Kukko Support 22/2

Fig 1: Differential, Disassembling And Assembling Remove/Install Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Transmission Housing
2. Adjusting Shim
   • For the differential.
   • To select the correct thickness, refer to DIFFERENTIAL, ADJUSTING .
3. Outer Race/Tapered Roller Bearing
   • Removing, refer to Fig 8.
   • Installing, refer to Fig 9.
4. Inner Race/Tapered Roller Bearing
   • Removing, refer to Fig 4.
   • Installing, refer to Fig 5.
5. Differential Housing
   • With a riveted final drive gear.
6. Inner Race/Tapered Roller Bearing
   • Removing, refer to Fig 6.
   • Installing, refer to Fig 7.
7. Outer Race/Tapered Roller Bearing
   • Removing, refer to Fig 2.
   • Installing, refer to Fig 3.
8. Washer
   • Installed position: the shoulder on the inner diameter faces the seal  DIFFERENTIAL.
9. Clutch Housing
10. Bolt
    • 33 Nm
    • Install with the threaded piece  DIFFERENTIAL.
11. Right Flange Shaft
12. Ring
    • Pry the ring off the flange shaft  DIFFERENTIAL with a screwdriver.
    • Installed position: the depression points away from threaded holes in the flange shaft.
    • Install the ring all the way by hand.
    • The ring must lock into the flange shaft.
13. Seal
    • For the right flange shaft
    • Replace when the transmission is installed. Refer to RIGHT FLANGE SHAFT AND SEAL .
14. Flange Shaft Pressure Spring
    • Installed behind the flange shaft.
15. Thrust Washer
    • Installed position: the collar faces toward the spring, and tab, if equipped, faces toward tapered ring.
16. Tapered Ring
    • Installed position: ball toward the differential housing.
17. Locking Ring
    • Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed.
18. Large Differential Bevel Gear
    • Installing, refer to Fig 11.
19. Differential Taper Axle
    • Remove using a drift.
    • Installing, refer to Fig 11.
20. Adapter Sleeve
    • To secure the differential bevel gear axle.
    • Removing and installing, refer to Fig 10.
21. Small Differential Bevel Gear
    • Installing, refer to Fig 11.
22. Threaded Piece
    • Installing Fig 11.
23. Thrust Washer Union
    • Install using transmission fluid.
24. Ring
    • Pry the ring off the flange shaft  DIFFERENTIAL with a screwdriver.
    • Installed position: the depression points away from threaded holes in the flange shaft.
    • Install the ring all the way by hand.
    • The ring must lock into the flange shaft.
25. Left Flange Shaft
26. Seal
    • For the left flange shaft.
    • Replace when the transmission is installed. Refer to LEFT FLANGE SHAFT AND SEAL .

Fig 2: Identifying Outer Race/Tapered Roller Bearing Pulled Off Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

Counter-support, for example, kukko Support 22/2

B -

Internal puller 46 to 58 mm, for example, kukko extractor 46-58 mm 21/7

Fig 3: Identifying Outer Race/Tapered Roller Bearing Pressed Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the washer beforehand.

Fig 4: Identifying Special Tool V.A.G 1582 Inserted On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Before installing the puller, mount the thrust Piece 40-105 onto the differential housing.

Fig 5: Identifying V.A.G 1582 And Inner Race/Tapered Roller Bearing Inserted On Special Tool VW 402

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 6: Identifying Separating Tool And Inner Race/Tapered Roller Bearing

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A -

Puller, for example, kukko puller 65-160 mm 18/1

B -

Separating tool 12 to 75 mm, for example, kukko separating tool 12-75 mm 17/1

Fig 7: Identifying Press Tools Inserted On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The cage wit the tapered rollers must rotate easily when being installed.

Fig 8: Identifying Outer Race/Tapered Roller Bearing Pulled Out Of Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

Counter-support, for example, kukko Support 22/2

B -

Internal puller 46 to 58 mm, for example, kukko extractor 46-58 mm 21/7

Fig 9: Identifying Tapered Roller Bearing Outer Race Pressed In Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Support the transmission housing directly under the bearing mount using the press Tube 3345.

Fig 10: Driving Out Spring Pin With Chisel, Inserting Chisel Into Circumferential Groove

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Removing 

-- Cover the inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.

-- Remove the adapter sleeve using a drift.

Installing 

-- Drive into the differential housing up to the stop.

Fig 11: Differential Bevel Gears And Differential Bevel Gear Axle, Installing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the thrust washer union with transmission fluid.

-- Install and secure both large differential planetary gears, for example, with a flange shaft.

-- Insert the small differential planetary gears 180° offset and pivot them into position.

-- Press the differential bevel gear -arrow A- up to the first small differential bevel gear.

-- Insert threaded pieces -arrow B- into the large differential planetary gears.

Installed position: shoulder faces the differential bevel gear

-- Install the differential bevel gear axle up the end position and secure it with a new spring pin.