Disassembly And Assembly: Differential

Special tools and workshop equipment required 

• Thrust Plate VW 402
• Punch VW 408 A
• Thrust Disc VW 412
• Thrust Piece 40-105
• Thrust Pad 3005
• Tube 60 mm Dia. VW 415 A
• Tube 3259
• Tube 3296
• Press Tool 3345
• Tapered Roller Bearing Puller V.A.G 1582
• Attachment to V.A.G 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

1. Transmission Housing
2. Adjusting Shim
   • For the differential.
   • Determining thickness, refer to DIFFERENTIAL, ADJUSTING .
3. Outer Race/Tapered Roller Bearing
   • Removing, refer to Fig 8.
   • Installing, refer to Fig 9.
4. Bearing Inner Race/Taper Roller Bearing
   • Removing, refer to Fig 4.
   • Installing, refer to Fig 5.
5. Differential Housing
   • With a riveted final drive gear.
   • The mount -arrow- for the right tapered roller bearing with right flange shaft insert, 12.5 mm longer.
6. Bearing Inner Race/Taper Roller Bearing
   • Removing, refer to Fig 6.
   • Transmission with right flange shaft: 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 collar on the inner circumference faces the seal.

9. Clutch Housing
10. O-ring
    • Not available on US/Canadian vehicles.
11. Ring
    • Not available on US/Canadian vehicles.
12. Bolt
    • Not available on US/Canadian vehicles.
13. Stub Shaft
    • Not available on US/Canadian vehicles.
14. Seal
    • Not available on US/Canadian vehicles.
15. Right Flange Shaft
16. Ring
    • Pry the ring off the flange shaft with a screwdriver. See item 15 in Fig 1.
    • Install the ring all the way by hand.
    • The ring must lock into the flange shaft.
17. Seal
    • For the flange shaft. See item 15 in Fig 1.
    • Replace when the transmission is installed. Refer to RIGHT FLANGE SHAFT AND SEAL .
18. Compression Spring for Flange Shaft
    • Installed behind the flange shaft.
19. Thrust Washer
    • Installed position: the collar faces toward spring, and tab, if equipped, faces toward tapered ring.
20. Tapered Ring
    • Installed position: ball toward the differential housing.
21. Locking Ring
    • Holds the tapered ring, thrust washer and compression spring in position when the flange shaft is removed
22. Large Differential Bevel Gear
    • Installing, refer to Fig 11.
23. Differential Taper Axle
    • Remove using a drift.
    • Installing, refer to Fig 11.
24. Adapter Sleeve
    • For securing the axle for the differential bevel gears.
    • Removing and installing, refer to Fig 10.
25. Small Differential Bevel Gear
    • Removing and installing, refer to Fig 10.
26. Threaded Piece
    • Installing, refer to Fig 11.
27. Thrust Washer Union
    • Install using transmission fluid.
28. Ring
    • Pry the ring off using a screwdriver alternating from side to side.
    • Installed position: the depression points away from the threaded holes in the flange shaft.
    • Install the ring all the way by hand.
    • The ring must lock into the flange shaft.
29. Left Flange Shaft
30. Seal
    • For the flange shaft.
    • Replace with the transmission installed. Refer to LEFT FLANGE SHAFT AND SEAL .

A - Counter support, for example, Kukko support 22/2

B - Internal puller 46 to 58 mm, for example, Kukko separating tool 12-75 mm 21/7

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

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

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

A - Counter support, for example, Kukko support22/2

B - Internal puller 46 to 58 mm, for example, Kukko separating tool 12-75 mm 21/7

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

Removing 

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

-- Remove the roll pin using a chisel.

Installing 

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

-- 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

-- Drive the differential planetary gear axle into its final position and secure with the spring pin.