Disassembly And Assembly: Differential

WARNING: This page is about a different car, the 2014 Volkswagen Tiguan, 2013 Volkswagen Tiguan, and 2012 Volkswagen Tiguan. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 408 A
Thrust Disc VW 412
Assembly Tool T40033/3
Thrust Piece T10266
Assembly Device 3291/2
Thrust Pad VW 472/1
Thrust Piece 40-105
Pressure Sleeve T10299
Kukko Extractor 56-70 mm 21/8
Kukko Support 22/2
2-Arm Puller 20/10

NOTE:

Heat the inner race/tapered roller bearing to 100 °C (212 °F) before installing.

Replace both tapered roller bearings together.

Adjust the differential when replacing the differential housing. Refer to DIFFERENTIAL, ADJUSTING .

Fig 1: Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing.

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A - Support, for example 22/2

B - Extractor 56-70 mm, for example, 21/8

Fig 2: Installing Outer Race/Tapered Roller Bearing Into Transmission Housing

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-- Support the transmission housing using the assembly device 3291/2 directly under the bearing mount.

Fig 3: Removing Inner Race/Tapered Roller Bearing In Transmission Housing And Bearing In Clutch Housing

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NOTE:

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

-- Tension the puller -A- in the area of the flattened side of differential housing below inner race.

A - 2-arm puller, for example 20/10

Fig 4: Installing Inner Race/Tapered Roller Bearing In Transmission Housing And Bearing In Clutch Housing

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NOTE:

Both differential housing tapered roller bearing inner races are installed in the same way.

Fig 5: Removing Outer Race/Tapered Roller Bearing From Clutch Housing

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A - Support, for example 22/2

B - Extractor 56-70 mm, for example 21/8

NOTE:

After removing, replace the damaged shim.

Fig 6: Installing Outer Race/Tapered Roller Bearing Into Clutch Housing

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-- Install the washer and the shim beforehand.

NOTE:

Note the installed position of the washer, the shoulder on inner diameter points toward seal.

Fig 7: Driving Out Spring Pin With Chisel, Inserting Chisel Into Circumferential Groove

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

-- Remove the adapter sleeve using a chisel.

Fig 8: Installing Spring Pin For Differential Bevel Gear Axle

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

-- Install the adapter sleeve to dimension -a- = 3 +/- 0.5 mm using a drift -1-.

Fig 9: Identifying Thrust Washer Union And Differential Housing

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-- Coat the thrust washer union with transmission fluid.

-- Install the thrust washer union so that the ridge -A- fits into the groove -B- in the differential housing.

Fig 10: Differential Bevel Gears And Differential Bevel Gear Axle, Installation

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-- Insert thrust washer union with transmission fluid. Refer to Fig 9.

-- Insert both large differential bevel gears and secure (for example, with stub 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 its final position and secure it with the spring pin. Refer to Fig 8.