Disassembly And Assembly: Differential: Notes

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, 2013 Volkswagen Beetle, and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

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 Tool 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
Inductive Heat Unit VAS 6414

Fig 1: 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

NOTE: Replace the shim -item 8- in DIFFERENTIAL OVERVIEW after removing it.

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

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-- Install the old shim into the clutch housing.

NOTE:

Pay attention to the shim installed position.

The collar on the inner circumference faces the seal.

Fig 3: Identifying Special Tool V.A.G 1582 Inserted On Inner Race/Tapered Roller Bearing

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

Fig 4: Identifying Inner Race/Tapered Roller Bearing Inserted On Special Tool VW 402

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

Fig 5: 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 6: Identifying Press Tools Inserted On Inner Race/Tapered Roller Bearing

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

Fig 7: Identifying Outer Race/Tapered Roller Bearing Pulled Out Of Transmission Housing

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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 8: Identifying Tapered Roller Bearing Outer Race Pressed In Transmission Housing

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

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

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