Drive Flange Circlips

Fig. 1 Final drive housing, disassembling / assembling
- mount in repair fixture




Fig. 2 Drive flange, removing
- remove using VW 391




Fig. 3 Drive flange, circlips, removing
- press oft with 2 screwdrivers When removing differential, remove only adjusting ring shaft (arrows)

NOTE
Flange is under spring pressure. Remove flange before removing circlips.




Fig. 4 Differential adjusting ring, removing / installing
- before removing mark position
- when installing reset to mark (arrow)




Fig. 5 Drive flange oil seal, installing
- lubricate between sealing lips with multipurpose grease
- drive in flush




Fig. 6 Bearing outer race, removing/installing
- heat adjusting ring to approximately 100°C (212°F) and press race out or in




Fig. 7 intermediate gear shaft, removing / installing
- before removing mark position
- when installing reset to mark (arrow)




Fig. 8 intermediate gear/bearing outer race, removing
- press out
- A = US 1099




Fig. 9 intermediate gear/bearing outer race, installing
- heat intermediate gear to approximately 100°C (212°F)




Fig. 10 Converter oil seal, driving in




Fig. 11 Pinion shaft oil seal, removing
- pry out of one-way clutch support




Fig. 12 Pinion shaft oil seal, installing e sealing lip faces toward converter




Fig. 13 One-way clutch support bearing outer race, removing
- do not interchange
- A = US 1099




Fig. 14 One-way clutch support bearing outer race, installing
- heat support to approximately 100°C (212°F) and press on outer race




Fig. 15 Pinion shaft bearing, removing
- bearing cannot be reused after removal




Fig. 16 Pinion shaft bearing, Installing
- heat to approximately 100°C (212°F) and press on




Fig. 17 Pinion shaft bearing outer race, installing




Fig. 18 ATF drillings, inserting 0-rings
- insert 0-rings (arrows) before installing one-way clutch support




Fig. 19 One-way clutch support, checking bail valve
- check sealing of ball valve by inserting piece of hose into hole (arrow) and sucking




Fig. 20 Final drive housing oil seal, Installing
- before installing adjust end play and insert shim
- sealing lip faces toward final drive




Fig. 21 Drive flange circlips, determining thickness
Note
When replacing circlip, drive flange shaft, differential housing or pinion/side gears, thickness of circlips (arrow) must be determined

- press drive flange shaft against pinion gear shaft
- press side gears against housing
- insert circlip into groove
- check that circlip does not jam at sides
- if YES use thinner circlip

Circlips available
Thickness (mm) Part No.
2.0 020 409 299
2.3 020 409 299 A




Fig. 22 Speedometer drive gear, disassembly
- always replace 0-ring 1
- press circlip 2 off pinion 3. Remove pinion from bearing shaft 4




Fig. 23 Drive flange, installing
- put circlip and spring washer in place before using installation tool 3109