Disassembly And Assembly: Differential: Notes

WARNING: This page is about a different car, the 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

Tapered Roller Bearing Puller VAG 1582
Attachment to VAG 1582 VAG 1582/3
Press Piece - Multiple Use VW 412
Press Plate VW 401
Press Plate VW 402
Punch VW 408A
Thrust Piece VW 473
Thrust Pad 30-205
Bearing Installer - Wheel Bearing 3144
Thrust Pad 2007
Torque Wrench 1332 40-200 Nm VAG 1332
Sleeve 40-21
Thrust Piece 40-105
Inductive Heat Unit VAS 6414
Puller - Kukko Internal - 46-56mm 21/7
Puller - Kukko Counterstay 22/2

Fig 1: Driving Tapered Roller Bearing Outer Race Out Of Clutch Housing Using Special Tools VW 408 & VW 473

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the right flange shaft seal first, refer to RIGHT FLANGE SHAFT AND SEAL .

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

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

Fig 3: Identifying Tool Assembly To Pull 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: Identifying Tool Assembly To Press In 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: Identifying Outer Race/Tapered Roller Bearing Pulled Out Of Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

Counter support, for example, Puller - Kukko Counterstay 22/2

B -

Internal puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm 21/7

Fig 6: Identifying Tool Assembly To Press In 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 with the Bearing Installer - Wheel Bearing 3144 directly under the bearing support.

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 Figure, installing, refer to Figure.	no surrounding groove

Fig 8: Differential Housing Allocation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check the hole in the differential housing for the adapter sleeve.

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