Differential, Disassembling And Assembling, AWD, Fwd With Front Axle Differential Lock

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Press Plate: VW402
Press Piece - Rod: VW408A
Press Piece - Rod: VW411
Press Piece - Multiple Use: VW412
Press Piece - Multiple Use: 30-23
Press Piece - Multiple Use: 40-105
Press Piece - Multiple Use: 3005
Press Piece - Bushing: 3259
Press Piece - Reverse Gear Syncro: 3296
Subframe Bushing Tool Kit: 3301
Bearing Installer - Wheel Bearing: 3345
-1- Internal Puller: VAS251615 (Kukko 21/7)
-2- Puller: VAS251417 (Kukko 18-1)
-3- Splitter: VAS251409 (Kukko 17-1)
-4- Counter Support: VAS251623 (Kukko 22/2)
-3- Two-Arm Puller: VAS251007 (Kukko 204-2)

Outer Race/Tapered Roller Bearing, Removing from Clutch Housing

Fig 1: Identifying Outer Race/Tapered Roller Bearing Pulled Off Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter Support: VAS251623 (Kukko 22/2)

B - Internal Puller: VAS251615 (Kukko 21/7)

-- Tension the internal puller -B- between the outer race/tapered roller bearing and the shim.

NOTE:

Tension the Internal Puller -B- between the outer race/tapered roller bearing and shim tightly -item ) OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK - List Item: Washer.

Replace the washer after removing it -item ) OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK - List Item: Washer.

The : VAS6775 (Kukko 21/8) can also be used instead of the : VAS251615 (Kukko 21-7).

Outer Race/Tapered Roller Bearing with Washer, Installing in Clutch Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- First, install the shim -item ) OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK - List Item: Washer.

Installation position of washer, shoulder on inner diameter points toward seal in clutch housing.

Bearing Inner Race/Tapered Roller Bearing, Removing

Fig 3: Identifying Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the : 40-105 on the differential housing.

-- Tension the : VAS251007 (Kukko 204-2) -A- in the near the flattened sides on the differential housing under the bearing inner race.

NOTE:

When removing the bearing inner race, make sure the hooks do not bend outward; if necessary tighten bolt -arrow-.

Heat the Bearing Inner Race/Tapered Roller Bearing and Press on It

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Wear safety gloves.

Bearing Inner Race/Tapered Roller Bearing, Removing

Fig 5: Identifying Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Puller: VAS251417 (Kukko 18-1)

B - Splitter: VAS251409 (Kukko 17-1)

Heat the Bearing Inner Race/Tapered Roller Bearing and Press on It

Fig 6: Identifying Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Wear safety gloves.

-- Mount the : 3301/3 from the : 3301 with the recess -arrow- (larger inner diameter) on the bearing inner race/tapered roller bearing.

Outer Race/Tapered Roller Bearing, Removing from Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter Support: VAS251623 (Kukko 22/2)

B - Internal Puller: VAS251615 (Kukko 21/7)

Outer Race/Tapered Roller Bearing, Installing in Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Support the transmission housing with the : 3345 directly under the bearing mount.

Differential Bevel Gear Axle and Adapter Sleeve, Removing

Fig 9: Removing Differential Bevel Gear Axle and Spring Pin

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use a 5 mm diameter pin punch -B- to remove the adapter sleeve -A- from the hole -arrow- on the differential housing.

NOTE:

If there is no hole -arrow- in the differential housing, remove the adapter sleeve as follows:

Fig 10: Differential Bevel Gear Axle And Roll Pin, Removal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Install the adapter sleeve -1- in the differential bevel gear axle -2- so that it is flush.

Place the differential under the press with the adapter sleeve -arrow- facing the : 30-23 .

Then, remove the differential bevel gear axle.

If necessary, remove the sheared parts of the adapter sleeve from the differential bevel box housing and remove the differential bevel gear axle.

Differential Bevel Gears, Installing

Fig 11: Differential Bevel Gears And Differential Bevel Gear Axle, Installation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the thrust washer union with transmission fluid.

-- Insert both large differential bevel gears and secure them (to the flange shaft, for example).

-- Insert the small differential bevel gears at an offset of 180° and move them into place.

-- Press the differential bevel gear axle -arrow A- up to the first small differential bevel gear.

-- Drive the differential bevel gear axle into its final position and secure it with the adapter sleeve. Refer to Fig 12.

Differential Bevel Gear Axle Adapter Sleeve, Installing

Fig 12: Installing Spring Pin for Differential Bevel Gear Axle

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Use a needle bearing drift to install the adapter sleeve -1- to the dimension -a- = 2.5 ± 0.5 mm.