Differential, Disassembling And Assembling: Notes

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Outer Race/Tapered Roller Bearing, Removing from Clutch Housing

Fig 1: Driving Tapered Roller Bearing Outer Race Out Of Clutch Housing Using Special Tools VW 408 & VW 473

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Before removing, remove the right flange shaft seal. Refer to OVERVIEW - DIFFERENTIAL .

Outer Race/Tapered Roller Bearing, Installing in Clutch Housing

Fig 2: Identifying Outer Race/Tapered Roller Bearing Pressed Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

There is no adjusting shim on the side of the clutch housing.

Inner Races/Tapered Roller Bearings, Removing

Fig 3: Identifying Tool Assembly To Pull Off Inner Races/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

Both tapered roller bearing inner races are removed from the differential housing in the same way.

Inner Races/Tapered Roller Bearings, Installing

Fig 4: Identifying Tool Assembly To Press In Inner Races/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Inner race/tapered roller bearing for transmission housing and clutch housing are installed using the same special tools

Outer Race/Tapered Roller Bearing, Removing from Transmission Housing

Fig 5: Identifying Outer Race/Tapered Roller Bearing Pulled Out Of Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter Support, for example, : VAS251623

B - Internal Puller, for example, : VAS251615

Outer Race/Tapered Roller Bearing, Installing in Transmission Housing

Fig 6: Identifying Tool Assembly To Press In Outer Race/Tapered Roller Bearing Into Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the washer under the outer race.

-- Support the transmission housing with the : 3144 directly under the bearing mount.

Differentiating the Spring Pins

Fig 7: Differentiating Spring Pins

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Dimension "a" mm	Identifying Feature
28.5 (short tension sleeve), Removing and installing. Refer to Fig 9.	Groove all the way around -arrows-
36.0 (long spring pin), Refer to Figure for removing and Figure, for installing.	No surrounding groove

Differential Housing Allocation

Fig 8: Differential Housing Allocation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check the hole in the differential housing for the spring pin.

The hole in the differential housing was modified due to the longer adapter sleeve.

Hole	Spring Pin Length (mm)
-A-	28.5 (short adapter sleeve)
-A- and -B-	36.0 (long adapter sleeve)

Adapter Sleeve with Surrounding Groove (Short Adapter Sleeve): Removing and Installing

Fig 9: Driving Out Spring Pin With Chisel, Inserting Chisel Into Circumferential Groove

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.