Differential, Removing and Installing

Differential, removing and installing

Notes:
- Refer to General repair instructions.
- Adjustments are required when replacing components marked 1); Refer to adjustment overview.

Secure final drive on a repair stand.





1. Vent sleeve
^ With rubber valve
^ Installation position; Refer to Fig. 4 .
2. Final drive housing 1).
3. Outer race for large taper roller bearing 1).
4. Shim "S1 " Note thickness Adjustment overview
5. Cover for final drive 1) With O-ring Replace O-ring Insert O-ring with oil
6. TORX-screw - 25 Nm
7. Seal, right
8. Hexagon socket-head bolt - 25 Nm
9. Flange shaft, right
^ Removing and installing; Refer to Fig. 2
10. Oil filler plug -35 Nm
^ Checking gear oil level in rear final drive
11. Differential with ring gear 1)
12. Oil drain plug, 35 Nm
13. Socket
^ Holds solenoid in position
^ Drive in onto stop
14. Solenoid
15. Outer race for small taper roller bearing 1)
16. Shim "S2" Note thickness Adjustment overview
17. Seal, left
18. Flange shaft, left
^ Removing and installing; Refer to Fig. 2
19. Hexagon socket-head bolt - 25 Nm
20. Cap
^ Installing; Refer to Fig 3





Fig. 1 Secure final drive on repair stand





Fig. 2 Removing and installing flange shaft





Fig. 3 Press in cover until stop





Fig. 4 Installation position vent sleeve
The vent sleeve must protrude from the housing by 13 mm (dimension -a) after being pressed in.
The slot in the rubber valve is located longitudinally in the direction of travel.

Removal
- Rear final drive removed

Special tools, testers and auxiliary equipment required





- Drip tray VAG 1306
- Clamp complete rear final drive into assembly bracket VW.
- Place drip tray underneath to collect oil.
- Drain gear oil.





- Remove left and right-hand flange shafts.
- To loosen the securing bolt, screw two bolts into the flange shaft and counter-hold with a lever.
- Mark flange shafts (left and right) and pull out.
- Unscrew securing bolts from cover for final drive.
- Take cover for final drive off axle housing and remove differential.

Installing
Install in reverse order.
- Insert differential.
- Replace O-ring for cover for final drive and oil when installing.
- Install cover for final drive onto axle housing and using diagonal sequence tighten to 25 Nm.
- Fill space between sealing lip and dust lip with a thin layer of sealing grease G052 128 Al.





- Insert flange shafts and tighten to 25 Nm.
- Top-up gear oil in rear final drive and check oil level.