Assembly overview - differential, four-wheel drive — VW

Assembly overview - differential, four-wheel drive
Note
Using the
inductive heater
VAS 6414
, heat tapered roller bearing inner races to about 100°C before installing.
Always renew both tapered roller bearings together as a set.
When renewing differential, adjust differential
Chapter
.
For some gearboxes the items
21 … 26
cannot be ordered as an individual replacement part anymore
Electronic Parts Catalogue
.
Gearbox housing
Tapered roller bearing inner race
Pulling off
Fig.
Pressing into gearbox housing
Fig.
Tapered roller bearing outer race
Pulling off
Fig.
Pressing into differential cage
Fig.
Differential
With final drive gear
Sender ring
Installed on some gearboxes
Drive off differential with drift
Pressing onto differential
Fig.
Tapered roller bearing inner race
Pulling off
Fig.
Pressing on
Fig.
Tapered roller bearing outer race
Pulling out
Fig.
Pressing in
Fig.
Shim
For differential
Determining thickness
Chapter
Will be damaged when removed
Renew after removal
Shim
Installation position: shoulder on inner circumference faces clutch housing
Clutch housing
Seal
Between gearbox and bevel box.
Renewing with manual gearbox installed
Chapter
.
With gearbox dismantled, can be driven in to stop with
thrust piece
T10144
.
Seal
Large seal between bevel box and manual gearbox
Replacing with bevel box removed
Chapter
Seal
Small seal for sealing stub shaft/bevel box on manual gearbox
Replacing with bevel box removed
Chapter
Bevel box
Removing and installing with manual gearbox installed
Chapter
Removing and installing with manual gearbox removed
Chapter
Seal
For right stub shaft.
Replacing with bevel box removed
Chapter
Bolt
Renew after removal
40 Nm +45°
Countersunk bolt
Screw into threaded piece
Item
35 Nm
Retaining ring
Insert in circumferential groove in stub shaft
Renew after removal
Seal
Renew after removal
Insert in groove in stub shaft.
Right stub shaft
Threaded piece
Availability
Electronic Parts Catalogue
Installing
Fig.
Large differential bevel gear
Availability
Electronic Parts Catalogue
Installing
Fig.
Differential pinion pin
Availability
Electronic Parts Catalogue
Drive out using drift
Installing
Fig.
Spring pin
Availability
Electronic Parts Catalogue
For securing differential pinion pin
Removing
Fig.
Installing
Fig.
Small differential bevel gear
Availability
Electronic Parts Catalogue
Removing and installing
Fig.
One-piece thrust washer
Availability
Electronic Parts Catalogue
Moisten with gear oil
Insert into differential
Fig.
Retaining ring
Holds left tapered ring, thrust washer and compression spring in position when stub shaft is removed.
Tapered ring
Installation position: taper towards differential cage
Thrust washer
Installation position: shoulder towards spring
Compression spring for left stub shaft
Installed behind left stub shaft.
Left stub shaft
Seal
For left stub shaft.
Renewing with gearbox installed
Chapter