Dismantling and assembling differential Page 1 of 8

Dismantling and assembling differential

Special tools and workshop equipment required

Gearbox support -VW 353-

Thrust plate -VW 401-

Thrust plate -VW 402-

Press tool -VW 407-

Press tool -VW 408 A-

Press tool -VW 412-

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Dismantling and assembling differential Page 2 of 8

Thrust plate -40-105-

Thrust plate -3005-

Tube -3259-

Tube -3296-

Tube -3345-

Torque wrench -V.A.G 1332-

Tapered roller bearing puller -V.A.G 1582-

Grip -V.A.G 1582/6-

-1-Internal puller -Kukko 21/7-

-4-Counterhold -Kukko 22/2-

Note

Heat tapered roller bearing inner race to 100° C before installing.

Always renew both tapered roller bearings together as a set.

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Dismantling and assembling differential Page 3 of 8

If tapered roller bearings, differential housing, gearbox housing or clutch housing are renewed, adjust
differential → Chapter.
1 - Gearbox
housing

2 - Bolt
 The final
drive gear
( → Item)
and the
differential
housing
( → Item) are
offered only
as an
assembly
 Individual
parts
→ Item,
→ Item,
→ Item ,
→ Item and
→ Item have
been
discontinued.

3 - Differential
cage
 The final
drive gear
( → Item)
and the
differential
housing
( → Item) are
offered only
as an
assembly
 Individual
parts
→ Item,
→ Item,
→ Item ,
→ Item and
→ Item have
been
discontinued.

4 - Final drive gear wheel

 The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly
 Individual parts → Item, → Item, → Item , → Item and → Item have been discontinued.
5 - Backing plate
 The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly
 Individual parts → Item, → Item, → Item , → Item and → Item have been discontinued.
6 - Nut, 40 Nm and turn 45° further
 Always renew
 The final drive gear ( → Item) and the differential housing ( → Item) are offered only as an assembly
 Individual parts → Item, → Item, → Item , → Item and → Item have been discontinued.

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Dismantling and assembling differential Page 4 of 8

7 - Clutch housing
8 - Shim
 For differential
 Determining thickness → Chapter

9 - Tapered roller bearing outer race

 Pulling out → Fig.
 Pressing in → Fig.
10 - Tapered roller bearing inner race
 Pulling off → Fig.
 Pressing on → Fig.
11 - Differential cage

12 - Tapered roller bearing inner race

 Pulling off → Fig.
 Pressing on → Fig.
13 - Tapered roller bearing outer race
 Pulling out → Fig.
 Pressing in → Fig.

14 - Washer
 → Chapter
15 - Seal
 For right flange shaft
 Left and right diameters differ.
 Allocation → Electronic parts catalogue “ETKA”
 Renewing with gearbox installed → Chapter
16 - Countersunk bolt, 25 Nm
 Screw into threaded piece ( → Item)
17 - Right flange shaft
 Do not interchange. Left and right flange shafts differ.
 Allocation → Electronic parts catalogue “ETKA”
 From gearbox date 19 05 3, with protective ring
 Do not interchange, different diameter of left and right-hand protective ring
 Allocation → Electronic parts catalogue “ETKA”
 Protective ring protects seal from dirt.
 Pry off protective ring using screwdriver on alternate sides
 Install with indentation facing away from threaded hole in flange shaft
 Press protective ring on to stop by hand
 Protective ring must engage in flange shaft.

18 - Compression spring for flange shaft

 Installed behind flange shafts

19 - Thrust washer
 Installation position: shoulder faces spring, lugs, if present, face tapered ring
20 - Tapered ring

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Dismantling and assembling differential Page 5 of 8

 With grooves to engage in thrust washer

 Installation position: taper towards differential cage

21 - Retaining ring
 Holds tapered ring, thrust washer and spring in position when flange shaft is removed
22 - Sun wheel
 Installing → Fig.
 Allocation → Electronic parts catalogue “ETKA”

23 - Differential pinion pin

 Drive out using drift
 Installing → Fig.
 Allocation → Electronic parts catalogue “ETKA”
24 - Spring pin
 For securing differential pinion pin
 Allocation → Electronic parts catalogue “ETKA”
 Removing and installing → Fig.

25 - Planet pinion
 Installing → Fig.
 Allocation → Electronic parts catalogue “ETKA”

26 - Threaded piece
 Installing → Fig.

27 - One-piece thrust washer

 Coat with gearbox oil when installing
28 - Left flange shaft
 Do not interchange. Left and right flange shafts differ.
 Allocation → Electronic parts catalogue “ETKA”
 From gearbox date 19 05 3, with protective ring
 Do not interchange, different diameter of left and right-hand protective ring
 Allocation → Electronic parts catalogue “ETKA”
 Protective ring protects seal from dirt.
 Pry off protective ring using screwdriver on alternate sides
 Install with indentation facing away from threaded hole in flange shaft
 Press protective ring on to stop by hand
 Protective ring must engage in flange shaft
29 - Seal
 For left flange shaft
 Left and right diameters differ.
 Allocation → Electronic parts catalogue “ETKA”
 Renewing with gearbox installed → Chapter

Pulling tapered roller bearing outer race

out of clutch housing
A - Counter support, e.g. -Kukko 22/2-
B - Internal puller, 46...58 mm, e.g. -Kukko

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Dismantling and assembling differential Page 6 of 8

21/7-

Note
After pulling out, check washer for damage
and renew if necessary.

Pressing tapered roller bearing outer race

into clutch housing
– First insert washer.

Pulling off tapered roller bearing inner

races
– Before fitting extractor, position thrust plate
-40-105- on differential cage.

Note
Both tapered roller bearing inner races are
pulled off the differential cage in the same
way.

Pressing on tapered roller bearing inner

race

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Dismantling and assembling differential Page 7 of 8

Note
The tapered roller bearing inner races for
gearbox housing and clutch housing are
pressed on with the same press tools.

Pulling tapered roller bearing outer race

out of gearbox housing
A - Counter support, e.g. -Kukko 22/2-
B - Internal puller, 46...58 mm, e.g. -Kukko
21/7-

Pressing tapered roller bearing outer race

into gearbox housing
– Support gearbox housing with tube -3345-
directly below bearing support.

Removing and
installing spring

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Dismantling and assembling differential Page 8 of 8

pin for differential

pinion pin
Removing

– Cover tapered
roller bearing
inner race to
prevent possible
damage and
ingress of metal
particles.
– Drive out spring
pin with chisel,
inserting chisel
into
circumferential
groove.

Installing
– Drive into
differential cage
to stop.

Installing differential bevel gears

– Lubricate one-piece thrust washer with

gearbox oil and install.
– Install both sun wheels and secure (e.g.
with flange shaft).

– Insert planet pinions offset 180° and pivot

into position.
– Press in differential pinion pin (-arrow A-)
to first planet pinion.
– Set threaded pieces (-arrows B-) in sun
wheels. Installation position: shoulder to
bevel gear
– Drive differential pinion pin into final
position and secure with spring pin.

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