5-speed manual gearbox 012/01W/0A9 — Dismantling and assembling differential — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

• Special tools named: puller

Don't miss

• There is a slot under the bearing seat in the differential housing for applying the puller (A).

📋 Procedure

1. After removing, check shims for damage.
2. Thrust pieceVW 472/1 is fitted with the cone in the outer race.
3. Support gearbox housing with removal and installation toolVW 459/2 directly below bearing support. [Note: There is a slot under the bearing seat in the differential housing for applying the puller (A).]
4. ⚠ Wear protective gloves! — Heat bearing to approx. 100° C, fit in position and press home. [Note: There is a slot under the bearing seat in the differential housing for applying the puller (A).]
5. ⚠ Wear protective gloves! — Heat bearing to approx. 100° C, fit in position and press home.

6. Screw out projections (A) and (B) until they contact outer race within recess in housing.
7. After removing, check shims for damage.
8. Thrust pieceVW 472/1 is fitted with the cone in the outer race.
9. Press left tapered roller bearing outer race into cover using thrust piece2050
10. Thrust piece2050 is fitted with the cone in the outer race.
11. ⚠ Wear protective gloves! — When installing crown wheel, guide it with centring pins (A) of local manufacture.
12. Allow to cool slightly before inserting securing bolts. Then tighten to specified torque.
13. Lubricate one-piece thrust washer with gear oil and install.
14. Insert sun wheels.
15. Insert planet pinions offset 180° and rotate into position (arrow).
16. Drive planet pinion pin into final position and secure.
17. Spring pin with circumferential groove: pull out using side-cutting pliers.
18. Spring pin without circumferential groove: drive out from behind using a drift.
19. Drive in spring pin to stop.

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