Disassembly And Assembly: Differential

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Tapered Roller Bearing Puller V.A.G 1582
Attachment to VAG 1582 V.A.G 1582/3
Thrust Disc VW 412
Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 408 A
Thrust Piece VW 473
Thrust Pad 30-205
Press Support-R&I Wheel Brg's 3144
Thrust Pad 2007
Torque Wrench (40-200 Nm) V.A.G 1332
Kukko Extractor 46-58 mm 21/7
Kukko Support 22/2

Fig 1: Driving Tapered Roller Bearing Outer Race Out Of Clutch Housing Using Special Tools VW408 & VW473

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the sleeve for the seal/flange shaft beforehand.

Fig 2: Pressing Outer Race/Tapered Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

There is no adjusting shim on the side of the clutch housing.

Fig 3: Pulling Off Inner Races/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

Both tapered roller bearing inner races are pulled off from the differential housing in the same way.

Fig 4: Pressing On Inner Races/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Both tapered roller bearing inner races are pressed on from the differential housing in the same way.

Fig 5: Pulling Outer Race/Tapered Roller Bearing 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 6: Pressing Outer Race/Tapered Roller Bearing Into Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the adjusting shim under the outer race.

-- Support the transmission housing using the press support-R&I wheel brg's 3144 directly under the bearing mount.

Fig 7: Differentiating Spring Pins

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Dimension "a" mm	Identifying feature
28.5 (short roll pin), Removing and installing, refer to Fig 9.	Groove all the way around -arrows-
36.0 (long roll pin), removing, refer to Fig 10, installing, refer to Fig 11.	no surrounding groove

Fig 8: Differential Housing Allocation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check the roll pin hole in the differential housing.

The hole in the differential housing was modified due to the longer roll pin.

Hole	Roll Pin Length (mm)
-A-	28.5 (short roll pin)
-A and B-	36.0 (long roll pin)

Fig 9: Driving Out Spring Pin With Chisel, Inserting Chisel Into Circumferential Groove

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Removing

-- Cover the taper roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.

-- Remove the roll pin using a chisel.

Installing

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

Fig 10: Spring Pin Without Surrounding Groove (Long Spring Pin), Removing: Press Out The Differential Bevel Gear Axle

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Roll pin is sheared off when it is removed.

-- Drive the remaining part of the roll pin out of the differential housing.

Fig 11: Spring Pin Without Surrounding Groove (Long Spring Pin), Installing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align the hole in the differential bevel gear axle to the hole in the differential housing.

-- Drive a new roll pin in, to dimension -a- = 3.0 mm using a drift -1-.

The roll pin must not come in contact with the transmission when the differential housing is installed.

Fig 12: Identifying Thrust Washer Union And Differential Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Also, the differential housing has a groove -B- all the way around it.

-- Insert the thrust washer union using transmission fluid.

-- Install the thrust washer union so that it engages into the groove -B- of the differential housing.

Fig 13: Differential Bevel Gears And Differential Bevel Gear Axle, Installing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the thrust washer union using 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 the threaded pieces -arrow B- into the large differential planetary gears.

Installed position: Collar toward the differential bevel gear

-- Drive the differential planetary gear axle into final position and secure with a roll pin.

Fig 14: Installation Position Of Thrust Washer For Tapered Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The collar -arrow- faces the pressure spring -B-.

Some transmissions are not equipped with ridges -A-.

The ridges -A- face the tapered ring -1-.