Differential, Disassembling and Assembling
Differential, disassembling and assembling 02Q, 6 Speed FWD M/T
Special tools, testers and auxiliary items required
^ Pressure plate VW 402
^ Punch VW 408 A
^ Punch VW 412
^ Thrust piece 40-105
^ Thrust piece 3005
^ Only transmission with right stub shaft
^ Thrust piece VW 473
Special tools, testers and auxiliary items required
^ Only transmission with right flange shaft
^ Tube VW 415 A
Special tools, testers and auxiliary items required
^ Tube 3259
^ Tube 3296
^ Tube 3345
^ Taper roller bearing puller V.A.G 1582
^ Attachment V.A.G 1582/6A
^ - 1 - Internal extractor Kukko 21/7
^ - 2 - Puller Kukko 18/1
^ - 3 - Separating tool Kukko 17/1
^ - 4 - Support Kukko 22/2
Note:
^ Heat inner race/tapered roller bearing to 100° C before installing.
^ Always replace both taper roller bearings together as a set.
^ Adjust differential.
1 - Transmission housing
2 - Adjustment shim
^ For differential
3 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in
4 - Tapered roller bearing inner race
^ Pulling out
^ Pressing in
5 - Differential housing
^ With riveted final drive gear
^ Mounting - arrow - for right tapered roller bearing with insert of right flange shaft, 12.5 mm longer
6 - Inner race/tapered roller bearing
^ Pulling out
^ Transmission with right stub shaft: Pressing on
^ Transmission with right flange shaft: Pressing on
7 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in
8 - Washer
9 - Clutch housing
10 - O-ring
^ Always replace
11 - Protective ring
12 - Countersunk bolt, 33 Nm
13 - Stub shaft
14 - Seal
^ For stub shaft, up to transmission build date 31 10 4
^ Replace with transmission installed
15 - Right drive flange
16 - Protective ring
^ Press on protective ring until stop by hand
^ Protective ring must engage with flange shaft
17 - Seal
^ Replacing with transmission installed
18 - Spring for flange shaft and stub shaft
^ Installed behind flange shaft or stub shaft
19 - Thrust washer
^ Installation position: Collar to compression spring, braces (if installed) to tapered ring
20 - Tapered ring
^ Installation position: Taper toward differential housing
21 - Circlip
^ Holds tapered ring, thrust washer and spring in position with flange shaft and stub shaft removed
22 - Large differential bevel gear
^ Installing
23 - Differential planetary gear axle
^ Drive out using drift
^ Installing
24 - Spring pin
^ For securing axle for differential bevel gears
^ Removing and installing
25 - Small differential bevel gear
^ Removing and installing
26 - Threaded piece
^ Installing
27 - Thrust washer union
^ Install coated with gear oil
28 - Protective ring
^ Pry out protective ring using a screwdriver alternately
^ Installation position: Depression points away from threaded holes in flanged shaft
^ Press on protective ring until stop by hand
^ Protective ring must engage with flange shaft
29 - Flange shaft
30 - Seal
^ For flange shaft
^ Replace with transmission installed
Pulling outer race/tapered roller bearing off clutch housing
A - Support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Note: Replace washer after pulling out.
Pressing outer race/tapered roller bearing into clutch housing
- Insert shim beforehand.
Note: Note installation position of washer, shoulder on inner diameter points toward sealing ring.
Pulling off inner race/tapered roller bearing
- Before installing puller, set thrust piece 40-105 onto differential housing.
Pressing on inner race/tapered roller bearing
Pulling off inner race/tapered roller bearing
A - Extractor, e.g. Kukko 18/1
B - Separating device 12 to 75 mm, e.g. Kukko 17/1
Transmission with right stub shaft: Pressing on inner race/tapered roller bearing
- Place thrust piece VW 473, with smaller outer diameter, onto inner race for tapered roller bearing.
It must be possible to lightly rotate the cage with tapered rollers when pressing in
Transmission with right flange shaft: Pressing on inner race/tapered roller bearing
It must be possible to lightly rotate cage with tapered rollers when pressing in
Pulling outer race/tapered roller bearing out of transmission housing
A - Support, e.g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Pressing in tapered roller bearing outer race into transmission housing
- Support transmission housing directly beneath bearing mount using tube 3345.
Removing and installing roll pin for differential bevel gear axle
Removing
- Cover inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.
- Drive out spring pin with chisel, inserting chisel into circumferential groove.
Installing
- Drive into differential housing up to stop.
Differential planetary gears, installing
- Insert thrust washer union with transmission fluid.
- Insert both large differential bevel gears and secure (e.g. with flange shaft).
- Insert small differential planetary gears 180° offset and pivot them into position.
- Press in differential bevel gear axle - arrow A - up to first small differential bevel gear.
- Insert threaded pieces - arrows B - in large differential bevel gears.
Installation position: Shoulder faces toward differential bevel gear
- Drive differential planetary gear axle into final position and secure with spring pin.