Differential, Disassembling And Assembling, Fwd

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 - Multiple Use: VW412
Press Piece - 60mm: VW415A
Press Piece - Multiple Use: 40-105
Press Piece - Multiple Use: 3005
Press Piece - Bushing: 3259
Press Piece - Reverse Gear Syncro: 3296
Bearing Installer - Wheel Bearing: 3345
Puller - Taper Roller Bearing: VAG1582
Puller - Taper Roller Bearing - Adapter 6A: VAG1582/6A
-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)
Inductive Heater: VAS6414

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)

NOTE:

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

Check the shim for damage after removing it. Replace, if necessary.

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.

-- Install the old washer -item ) OVERVIEW - DIFFERENTIAL, FWD - List Item: Washer into the clutch housing.

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

Inner Race/Tapered Roller Bearing, Removing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Before installing the puller, mount the : 40-105 on the differential housing.

Heat the 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.

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

WARNING:

Wear safety gloves.

Inner Race/Tapered Roller Bearing, Removing

Fig 5: Identifying Separating Tool And 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 Inner Race/Tapered Roller Bearing and Press on It

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

WARNING:

Wear safety gloves.

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)

NOTE:

The : VAS6775 (Kukko 21/8) can also be used instead of the : 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 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 drift -B- to remove the adapter sleeve -A- from the hole -arrow- on the differential housing.

NOTE:

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

Fig 10: Driving Out Spring Pin With Chisel, Inserting Chisel Into Circumferential Groove

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Position a chisel in the surrounding groove in order to drive out the adapter sleeve.

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.

-- Insert the threaded pieces -B arrows- into the large differential bevel gears.

Installed position: shoulder faces the differential bevel gear

-- Install the differential bevel gear axle up to the final position and secure it with a new 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.

-- Using a drift, install the adapter sleeve -1- to the dimension -a- = 2.5 ± 0.5 mm.