Differential, Disassembling and Assembling Special tools

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Buck Ellis
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1 Differential, Disassembling and Assembling Special tools VAG 1582 Bearing puller VAG 1582/3 Grip piece VW 412 Thrust disc Thrust piece VW 401 Thrust plate VW 402 Thrust plate

2 VW 408 A Punch VW 473 Thrust piece Thrust pad 3144 Press support 2007 Thrust pad Note: Heat tapered roller bearing inner race to 100 C (212 F) before installing. Always replace both tapered roller bearings together as a set. If differential housing, transmission housing or clutch housing tapered roller bearings are replaced, adjust differential.

3 1 Transmission housing 2 Bolt 3 Differential cage Bolt to final drive gear 4 Final drive gear Riveted in production Is paired with output shaft, only replace as a set Pressing off refer to Fig. 9 Installation position refer to Fig. 10

4 Heat to 100 C (212 F) before installing Mount to differential housing Fig. 11 Bolting refer to Fig Plate 6 Nut 70 Nm (52 ft. lbs.) 7 Shim For differential Determining thickness 8 Tapered roller bearing outer race Pulling out refer to Fig. 5 Pressing in refer to Fig. 6 9 Tapered roller bearing inner race Pulling off refer to Fig. 3 Pressing on refer to Fig Differential housing With riveted final drive gear When replacing final drive gear drill out rivet heads refer to Fig. 8 Attaching final drive gear with bolts refer to Fig. 12 Both sides are chamfered to accept tapered rings (item 21) in transmissions with springs behind flange shafts refer to Fig Speedometer drive gear Install on differential housing before pressing on inner race

5 12 Tapered roller bearing inner race Pulling off refer to Fig. 3 Pressing on refer to Fig Tapered roller bearing outer race Driving out refer to Fig. 1 Pressing in refer to Fig Clutch housing 15 Sleeve To accept oil seal (item 16) 16 Oil seal 17 Cone-head bolt 25 Nm (18 ft. lbs.) Bolt into threaded piece (item 25) 18 Flange shaft 19 Spring for flange shaft Installed behind flange shafts 20 Thrust washer Installation position: Shoulder toward spring, tongue to tapered ring 21 Tapered ring With grooves to secure thrust washer Installation position: -Taper toward differential housing

6 22 Circlip Ensures tapered ring, thrust washer and spring are held in position when flange shaft is removed 23 One-piece thrust washer Coat with gear oil when installing 24 Differential side gear Installing see Fig Threaded piece Installing refer to Fig Differential pinion shaft Drive out with drift Installing refer to Fig Spring pin Removing and installing refer to Fig Differential pinion gear Installing refer to Fig Differential side gear Installing refer to Fig. 14 Fig. 1 Driving tapered roller bearing outer race out of clutch housing

7 Fig. 2 Pressing tapered roller bearing outer race into clutch housing

8 Note: No shim is installed in the clutch housing end. Fig. 3 Pulling off tapered roller bearing inner race

9 Position thrust piece on differential housing. Install puller. Note: Bot tapered roller bearing inner races are pulled off the differential housing in the same way Fig. 4 Pressing on tapered roller bearing inner race

10 Note: The tapered roller bearing inner races for the transmission and clutch housings are pressed on with the same tools. Fig. 5 Pulling tapered roller bearing outer race out of transmission housing

11 A Counter support, e.g. Kukko 22/2 B Internal puller, mm, e.g. Kukko 2117 Fig. 6 Pressing tapered roller bearing outer race into transmission housing

12 Install shim under outer race. Support transmission housing with sleeve 3144 directly below bearing mounting. Fig.7 Both sides of differential housing are chamfered (arrow) to accept tapered rings/springs

13 Fig. 8 Drilling out rivet heads

14 Drill out rivet heads with 12 mm drill on countersunk side and drive-out with drift. Note: Clean differential before and after drilling, and protect tapered roller bearing from drillings. Fig. 9 Pressing off final drive gear

Place thrust piece 40-105 on differential housing.

15 Place thrust piece on differential housing. Fig. 10 Installation position of final drive gear

16 The circular groove -A- faces toward bolt-on side of differential. Fig. 11 Heating final drive gear to approx. 100 C (212 F) and installing

17 Use bolts -A- from repair kit to guide final drive gear into position during installation. Fig. 12 Bolting final drive gear and differential housing together

18 Use special bolts with plates and nuts as specified in the parts catalog. Fig. 13 Removing and installing differential pinion shaft spring pin

Removing Installing Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.

19 Removing Installing Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles. Insert chisel into circumferential groove and drive-spring pin out. Drive spring pin fully into differential housing. Fig. 14 Installing differential side gears and pinion gears

20 Lubricate one piece thrust washer with gear oil and install. Install both side gears and secure (e.g. with flange shaft). Turn pinion gears through 180 and pivot into position. Push pinion shaft (arrow -A-) in until first pinion gear is contacted. Position threaded piece (arrow-b-) in side gears (installation position: step toward side gear) Drive pinion shaft into final position and secure with spring pin.

Wheel bearing housing, removing and installing

Page 1 of 17 40-54 Wheel bearing housing, removing and installing Removing - Remove wheel trim. On light alloy wheels use puller in vehicle tool kit to remove trim cap. - Remove bolt for drive axle. WARNING!