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Component Disassembly & Reassembly: Differential: Disassembly

  1. Ring gear is attached to differential housing by rivets on 5-speed. Drill out rivet heads with a 15/32" (12 mm) drill bit, then knock out rivets with a drift. Remove ring gear bolt lock plate and remove bolts on 4-speed. Place assembly in a press and press off differential ring gear. See Fig 1 .
    Fig 1: Exploded View of Differential Assembly
    G95F55793Courtesy of VOLKSWAGEN UNITED STATES, INC.
    NOTE: Ring gear is reinstalled with special bolts, washers and nuts. Serrations on shank of bolts lock bolt in housing.
  2. Remove snap rings from differential pinion shaft, and drive shaft out of housing. Remove snap rings securing side gears to axle drive flange shafts, and remove shafts from housing. Remove pinions and side gears. Rotate thrust cage and remove from housing.
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