Differential Cover, Manual Transaxle

Special tools, testers and auxiliary items required:
^ Thrust plate VW401
^ Press tool VW407
^ Press tool VW412
^ Tube VW415a
^ Spacer sleeve VW472/2
^ Thrust ring 2006A
^ Internal puller 37-46 mm (e.g. Kukko 21/6)
^ Internal puller 46-58 mm (e.g. Kukko 21/7)
^ Counter support (e.g. Kukko 22/2)





1. End cover
^ If replaced:
- Redetermine thickness of circlip -5-.
- Redetermine shims for Torsen differential.
2. Oil drain plug, 40 Nm
3. Cylinder roller bearing for input shaft
^ Pulling out see Fig. 1
^ Pressing in flush see Fig. 2
4. Ball bearing for input shaft
^ Removing see Fig. 3
^ Installing see Fig. 4
^ If replaced, redetermine thickness of circlip -5
5. Circlip
^ Redetermine thickness
^ Installing see Fig. 4
6. Baffle plate
^ Replace
^ Removing see Fig. 3
^ Installing and peening in position when replacing ball bearing for input shaft see Fig. 5
^ Installing and peening in position when replacing end cover see Fig. 6
7. Needle - bearing for Torsen differential
^ Pulling out see Fig. 7
^ Driving in see Fig. 8





Fig. 1 Pulling cylinder roller bearing for input shaft out of end cover
A - Internal puller 37-46 mm, e.g. Kukko 21/6
B - Spindle from counter support Kukko 22/2





Fig. 2 Pressing cylinder roller bearing for input shaft flush into end cover
^ Tube VW 415a with shoulder towards press tool VW 412





Fig. 3 Removing ball bearing for input shaft from end cover
- Position screwdriver as illustrated, drive into baffle plate (arrow) and lever out.
- Remove circlip.
- Take out bearing, remove peening indentations if necessary.





Fig. 4 Installing ball bearing for input shaft in end cover
Installation position of circlip:
^ Ends of circlip (arrows), point towards needle bearing

Note: The thickness of the circlip must be redetermined if the bearing or the end cover are replaced.

- Determining circlip for ball bearing for input shaft:
- Press ball bearing outer race onto stop.
- Determine the thickest circlip that can still just be fitted.
Axial play: max. 0.08 mm
- Determine circlip from table.





The following circlips are available:
- Fit circlip.





Fig. 5 Peening baffle plate in position when replacing ball bearing for input shaft
- Use a blunt punch with a ball shaped end (ball diameter 5 mm) to peen in position.
- Insert baffle plate.
- First peen at points marked with -arrows 1-.
- Then peen at points marked with arrows
2. at distance -a- from first position.
^ Dimension a = 5 mm
- Observe position and diameter of peening positions:
^ Dimension b = 2 mm
^ Dimension c = 3 mm





Fig. 6 Peening baffle plate in position when replacing end cover
- Use a blunt punch with a ball shaped end (ball diameter 5mm) to peen in position.
- Insert baffle plate.
- Peen in first peening point (arrow) at distance -d- from the center line of the two shafts.
^ Dimension d = 10 mm
- Observe position and diameter of peening positions.
^ Dimension b = 2 mm
^ Dimension c = 3 mm
- Peen in second and third peening points in same manner at distance -a-
^ Dimension a = 70 mm





Fig. 7 Pulling needle bearing for Torsen differential out from end cover
A - Internal puller 46-58 mm, e.g. Kukko 21/7
B - Spindle from counter support Kukko 22/2





Fig. 8 Driving needle bearing for Torsen differential flush into end cover
- Fit press plate VW 412 onto bearing with shoulder facing up.