LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Volkswagen >> 2006 >> Passat Value Edition, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Final Drive, Differential - 02Q >> 39 Final Drive, Differential >> Disassembly And Assembly >> Differential
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Disassembly And Assembly: Differential

Special tools and workshop equipment required 

NOTE:

Heat the inner race/tapered roller bearing to 100°C (212°F) before installing.

Replace both tapered roller bearings together.

Adjust the differential, refer to DIFFERENTIAL, ADJUSTING  when replacing the tapered roller bearing, differential housing, transmission housing or clutch housing.

Fig 1: Identifying Disassembling And Assembling Overview: Differential
GWWN39-10188Courtesy of VOLKSWAGEN UNITED STATES, INC.
  1. Transmission Housing
  2. Adjusting Shim
  3. Outer Race/Tapered Roller Bearing
    • Removing, refer to Fig 8.
    • Installing, refer to Fig 9.
  4. Bearing Inner Race/Taper Roller Bearing
    • Removing, refer to Fig 4.
    • Installing, refer to Fig 5.
  5. Differential Housing
    • With a riveted final drive gear.
    • The mount -arrow- for the right tapered roller bearing with right flange shaft insert, 12.5 mm longer.

      For the correct allocation.

  6. Bearing Inner Race/Taper Roller Bearing
    • Removing, refer to Fig 6.
    • Transmission with right flange shaft: installing, refer to Fig 7.
  7. Outer Race/Tapered Roller Bearing
    • Removing, refer to Fig 2.
    • Installing, refer to Fig 3.
  8. Washer

    Installed position: the collar on the inner circumference faces the seal.

    For the correct allocation.

  9. Clutch Housing
  10. O-ring
    • Not available on US/Canadian vehicles.
  11. Ring
    • Not available on US/Canadian vehicles.
  12. Bolt
    • Not available on US/Canadian vehicles.
  13. Stub Shaft
    • Not available on US/Canadian vehicles.
  14. Seal
    • Not available on US/Canadian vehicles.
  15. Right Flange Shaft

    For the correct allocation.

  16. Ring
    • Pry the ring off the flange shaft with a screwdriver. See item 15 in Fig 1.
    • Install the ring all the way by hand.
    • The ring must lock into the flange shaft.
  17. Seal
  18. Compression Spring for Flange Shaft
    • Installed behind the flange shaft.
  19. Thrust Washer
    • Installed position: the collar faces toward spring, and tab, if equipped, faces toward tapered ring.
  20. Tapered Ring
    • Installed position: ball toward the differential housing.
  21. Locking Ring
    • Holds the tapered ring, thrust washer and compression spring in position when the flange shaft is removed
  22. Large Differential Bevel Gear
    • Installing, refer to Fig 11.
  23. Differential Taper Axle
    • Remove using a drift.
    • Installing, refer to Fig 11.
  24. Adapter Sleeve
    • For securing the axle for the differential bevel gears.
    • Removing and installing, refer to Fig 10.
  25. Small Differential Bevel Gear
    • Removing and installing, refer to Fig 10.
  26. Threaded Piece
    • Installing, refer to Fig 11.
  27. Thrust Washer Union
    • Install using transmission fluid.
  28. Ring
    • Pry the ring off using a screwdriver alternating from side to side.
    • Installed position: the depression points away from the threaded holes in the flange shaft.
    • Install the ring all the way by hand.
    • The ring must lock into the flange shaft.
  29. Left Flange Shaft
  30. Seal
    • For the flange shaft.

      For the correct allocation.

    • Replace with the transmission installed. Refer to LEFT FLANGE SHAFT AND SEAL .
Fig 2: Identifying Outer Race/Tapered Roller Bearing Pulled Off Clutch Housing
GWWN39-0733Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Counter support, for example, Kukko support 22/2

B - Internal puller 46 to 58 mm, for example, Kukko separating tool 12-75 mm 21/7

NOTE:

Replace the washer.

Fig 3: Identifying Outer Race/Tapered Roller Bearing Pressed Into Clutch Housing
GWWN39-0734Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:

Pay attention to the shim installed position.

The collar on the inner circumference faces the seal.

Fig 4: Identifying Special Tool V.A.G 1582 Inserted On Inner Race/Tapered Roller Bearing
GWWN39-10003Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Before installing the puller, mount the thrust piece 40-105 onto the differential housing.

Fig 5: Identifying V.A.G 1582 And Inner Race/Tapered Roller Bearing Inserted On Special Tool VW 402
GWWN39-10004Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig 6: Identifying Separating Tool And Inner Race/Tapered Roller Bearing
GWWN39-10005Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Puller, for example, Kukko puller 65-160 mm 18/1

B - Separating tool 12 to 75 mm, for example, Kukko separating tool 12-75 mm 17/1

Fig 7: Identifying Press Tools Inserted On Inner Race/Tapered Roller Bearing
GWWN39-10189Courtesy of VOLKSWAGEN UNITED STATES, INC.

The cage with the tapered rollers must rotate easily when being installed.

Fig 8: Identifying Outer Race/Tapered Roller Bearing Pulled Out Of Transmission Housing
GWWN39-1102Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Counter support, for example, Kukko support 22/2

B - Internal puller 46 to 58 mm, for example, Kukko separating tool 12-75 mm 21/7

Fig 9: Identifying Tapered Roller Bearing Outer Race Pressed In Transmission Housing
GWWN39-0727Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Support the transmission housing directly under the bearing mount using the press tool 3345.

Fig 10: Identifying Spring Pin Driven Out With Chisel, Inserting Chisel Into Circumferential Groove
GWWV39-1649Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing 

-- Cover the inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.

-- Remove the roll pin using a chisel.

Installing 

-- Drive into the differential housing up to the stop.

Fig 11: Identifying Differential Bevel Gears And Differential Bevel Gear Axle
GWWN39-0050Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Insert the thrust washer union with transmission fluid.

-- Install and secure both large differential planetary gears, for example, with a flange shaft.

-- Insert the small differential planetary gears 180° offset and pivot them into position.

-- Press the differential bevel gear -arrow A- up to the first small differential bevel gear.

-- Insert threaded pieces -arrow B- into the large differential planetary gears.

Installed position: shoulder faces the differential bevel gear

-- Drive the differential planetary gear axle into its final position and secure with the spring pin.

scientia non olet · About LEMON Manuals