Assembly overview - differential, all-wheel drive — VW

Assembly overview - differential, all-wheel drive
Note
Using the
inductive heater
VAS 6414
, heat tapered roller bearing inner races to about 100°C before installing. Wear protective gloves when doing this.
Always renew both tapered roller bearings together as a set.
If tapered roller bearings, differential, gearbox housing or clutch housing is renewed, adjust differential
Chapter
.
Gearbox housing
Shim
For differential
Determining thickness
Chapter
Tapered roller bearing outer race
Pulling out
Fig.
Pressing in
Fig.
Tapered roller bearing inner race
Pulling off
Fig.
Pressing on
Fig.
Differential
With differential bevel gears, one-piece thrust washer, differential pinion pin and final drive gear
Removing differential bevel gears, one-piece thrust washer and differential pinion pin
Fig.
Installing differential bevel gears, one-piece thrust washer and differential pinion pin
Fig.
Tapered roller bearing inner race
Pulling off
Fig.
Pressing on
Fig.
Tapered roller bearing outer race
Pulling out
Fig.
Pressing in
Fig.
Plate
Installation position: shoulder on inner circumference faces clutch housing
Allocation
Electronic Parts Catalogue
Clutch housing
Seal
Installed in manual gearbox between manual gearbox and bevel box
Renewing
Chapter
Seal
For right flange shaft
Left and right diameters differ
Renewing with manual gearbox with bevel box installed
Chapter
Hexagon bolt
Qty. 4
Renew after removal
Specified torque:
Item
Countersunk bolt
Bolt with threaded piece of differential
33 Nm
Right flange shaft
Removing and installing
Chapter
Seal
On right flange shaft in bevel box
Is replaced working from right flange shaft sealing ring end (
Item
)
Remove from right flange shaft to replace needle bearing (polygon bearing
Item
)
Chapter
Needle bearing (polygon bearing)
Renewing
Chapter
Retaining ring
For needle roller bearing (polygon bearing)
Renew after removal
Bevel box
Removing and installing
Chapter
Chapter
Seal
Installed between bevel box and manual gearbox in bevel box
Renewing
Chapter
Retaining ring
Holds tapered ring, thrust washer and spring in position when flange shaft is removed
Tapered ring
With grooves to engage in thrust washer
Installation position: taper towards differential housing
Thrust washer
Installation position: shoulder faces spring, lugs face tapered ring
Compression spring
For left flange shaft
Installed behind left flange shaft
Left flange shaft
Depending on vehicle equipment with protective ring
Allocation
Electronic Parts Catalogue
Lever protective ring off left flange shaft with a screwdriver, alternating sides.
Install with indentation facing away from threaded hole in flange shaft
Push on protective ring to stop by hand
Protective ring must engage in flange shaft
Seal
For left flange shaft
Left and right diameters differ
Renewing with gearbox installed
Chapter