Differential, Disassembling and Assembling
Differential, disassembling and assembling - 6 Spd. Manual Transmission 01E
Special tools, testers and auxiliary items
^ Drift VW 295
^ Press plate VW 401
^ Press plate VW 402
^ Press tool VW 407
^ Press tool VW 408 A
^ Press tool VW 412
^ Press tool VW 442
^ Press tool 40-21
^ Thrust plate 40-105
^ Thrust pad 2050
^ Drift 3138
^ Tapered roller bearing puller V.A.G 1582 and V.A.G 1582/6
^ Two-arm puller Kukko 44/2
Note:
^ Observe general repair instructions.
^ Replace both tapered roller bearings of the differential together. Use same make if possible.
^ Adjustments are required when replacing components marked 1)
1 - Cover for final drive 1)
2 - O-ring
^ Always replace
^ Insert with oil
3 - Final drive housing 1)
4 - Shim "S2"
^ Note thickness
^ Adjust
5 - Outer race for small tapered roller bearing 1)
6 - Inner race for small tapered roller bearing 1)
7 - Bolt, 60 Nm + turn 45° further
^ Always replace
^ Lightly tighten bolts then tighten diagonally to correct torque
8 - Differential housing 1)
9 - Ring gear 1)
^ Paired with drive pinion (final drive set)
^ Select correct version according to code letters
^ Drive off housing with a punch
^ Install on differential housing
10 - Spring pin
^ For securing planet pinion axis shaft
^ Drive in flush
11 - Inner race for large tapered roller bearing 1)
12 - Outer race for large tapered roller bearing 1)
13 - Shim "S1"
^ Note thickness
^ Adjust
14 - Threaded piece
15 - Sun wheel
16 - Planet pinion
17 - Planet pinion axis shaft
^ Knock out with drift
^ Drive in carefully so that the thrust washers are not damaged
^ Secure with spring pin
18 - Shim
^ Re-determining thickness
19 - Thrust washer
^ Check for cracks
Knocking outer race of small tapered roller bearing out of housing
- After removing check shims for damage.
Pressing outer race of small tapered roller bearing into housing (press against stop)
- Position outer race using VW 295 and light even blows with a hammer.
- Drive in onto stop as shown in illustration.
Pulling off inner race for small tapered roller bearing
A - Two arm puller, e.g. Kukko 44/2
Pressing on inner race for small tapered roller bearing
CAUTION:
Wear protective gloves.
- Heat bearing to approx. 100° C, fit in position and press home.
Pulling off inner race for large tapered roller bearing
- Before fitting extractor position press piece 40-105 on differential housing.
Pressing on inner race for large tapered roller bearing
CAUTION:
Wear protective gloves.
- Heat bearing to approx. 100° C, fit in position and press home.
Driving outer race for large tapered roller bearing out of cover
- After removing check shims for damage.
Pressing outer race for large tapered roller bearing into cover
Driving ring gear off housing
Installing ring gear
CAUTION:
Wear protective gloves.
- When fitting ring gear guide centralizing pins -A- (local manufacture).
- Heat ring gear to approx. 100 degrees C and install.
Installing sun wheels and planet pinions
- If sun wheels have been replaced, measure and select new shims.
- Insert sun wheels with measured shims.
- Install planet pinions spaced 180 degrees apart, and rotate into position (arrow).
- Fit and align thrust washers.
- Insert threaded pieces.
- Drive planet pinion shaft into final position and secure.
Adjusting differential bevel gears
- Insert sun wheels with thinnest shims (0.5 mm).
- Insert planet pinions with thrust washers spaced 180° apart.
Note:
Do not now interchange bevel gears and thrust washers.
- Drive in planet pinion axis shaft.
- Press planet pinions outward.
- Press sun wheels in direction indicated (arrows), and check the amount of play.
- Determine thickest shims for sun wheels (on each side) which can still just be inserted. The same thickness of shim should be used on both sides.
- Identify shims according to table.
The following shims are available:
Note:
The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the differential bevel gears (arrow).