Differential, Disassembling And Assembling: Notes

Fig 1: Identifying Special Tools And Workshop Equipment

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Special tools and workshop equipment required

Puller - Taper Roller Bearing: VAG1582
Puller - Taper Roller Bearing - Adapter 3: VAG1582/3
Press Piece - Multiple Use: VW412
Press Plate: VW401
Press Plate: VW402

Fig 2: Identifying Special Tools And Workshop Equipment

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Special tools and workshop equipment required

Press Piece - Rod: VW408A
Press Piece - Multiple Use: VW 473
Press Piece - Multiple Use: 30-205
Bearing Installer - Wheel Bearing: 3144
Bearing Installer - Taper Roller Bearing: 2007
Torque Wrench 1332 40-200Nm: VAG1332

Special tools and workshop equipment required

Press Piece - Multiple Use: 40-105

Fig 3: Press Piece - Multiple Use 40-105
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Inductive Heater: VAS6414

Fig 4: Identifying Heater
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-1- Internal Puller: VAS251615

Fig 5: Identifying Kukko Puller
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-4- Counter Support: VAS251623

Outer Race/Tapered Roller Bearing, Removing from Clutch Housing

Fig 6: Driving Tapered Roller Bearing Outer Race Out Of Clutch Housing Using Special Tools VW 408 & VW 473

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

Outer Race/Tapered Roller Bearing, Installing in Clutch Housing

Fig 7: Identifying Outer Race/Tapered Roller Bearing Pressed Into Clutch Housing

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

Inner Races/Tapered Roller Bearings, Removing

Fig 8: Identifying Tool Assembly To Pull Off Inner Races/Tapered Roller Bearing

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-- Before installing the puller, mount the Press Piece - Multiple Use: 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 9: Identifying Tool Assembly To Press In Inner Races/Tapered Roller Bearing

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

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A - Counter Support, for example, Counter Support Counter Support: VAS251623

B - Internal Puller, for example, Internal Puller Internal Puller: VAS251615

Outer Race/Tapered Roller Bearing, Installing in Transmission Housing

Fig 11: Identifying Tool Assembly To Press In Outer Race/Tapered Roller Bearing Into Transmission Housing

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-- Install the washer under the outer race.

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

Differentiating the Spring Pins

Fig 12: Differentiating Spring Pins

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Dimension "a" mm	Identifying Feature
28.5 (short tension sleeve), Removing and installing, Refer to Fig 14.	Groove all the way around -arrows-
36.0 (long spring pin), Refer to Figure for removing and Refer to Figure, for installing.	No surrounding groove

Differential Housing Allocation

Fig 13: Differential Housing Allocation

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-- 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 14: Driving Out Spring Pin With Chisel, Inserting Chisel Into Circumferential Groove

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