Assembly overview - differential, four-wheel drive and front-wheel drive with front differential lock — VW

Assembly overview - differential, four-wheel drive and front-wheel drive with front differential lock
Note
Heat tapered roller bearing inner races to about 100°C with the
inductive heater
VAS 6414
before installing. Wear protective gloves when doing this.
Always renew both tapered roller bearings together as a set.
If tapered roller bearings, differential cage, 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 cage
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.
Washer
Installation position: shoulder on inner circumference faces clutch housing.
Allocation
Electronic Parts Catalogue
Clutch housing
Seal
Renew after removal
Four-wheel drive, between gearbox and bevel box.
Renewing
Chapter
Front-wheel drive with front differential lock, between manual gear box and front differential lock.
Renewing
Chapter
Seal
For right flange shaft
For four-wheel drive: renew with bevel box installed
Chapter
For front-wheel drive with front differential lock: renew with front differential lock installed
Chapter
Hexagon bolt
Qty. 4
Renew after removal
40 Nm + 90°
Countersunk bolt
Renew after removal
33 Nm
Right flange shaft
For four-wheel drive: removing and installing
Chapter
.
For front-wheel drive with front differential lock, removing and installing
Chapter
Seal
Renew after removal
Four-wheel drive: for flange shaft in bevel box
Chapter
.
For four-wheel drive: renew working from seal end
Item
Chapter
Front-wheel drive with front differential lock: for flange shaft in Haldex coupling.
For front-wheel drive with front differential lock: renew working from seal end
Item
Chapter
Needle bearing (polygon bearing)
All-wheel drive only
Renewing
Chapter
Retaining ring
Renew after removal
For four-wheel drive: for needle roller bearing (polygon bearing).
For front-wheel drive with front differential lock: for right flange shaft
Bevel box for four-wheel drive, front differential for front-wheel drive
Four-wheel drive - seals, flange shaft mounting and output flange mounting
Chapter
.
Depending on equipment level, the front differential lock is installed in conjunction with petrol engine
Chapter
.
Front-wheel drive - renew seals and flange shaft mounting
Chapter
Chapter
Seal
Renew after removal
Four-wheel drive, between bevel box and manual gearbox
Four-wheel drive: renew with bevel box removed
Chapter
.
Front-wheel drive with front differential lock, between front differential lock and manual gearbox.
Front-wheel drive with front differential lock, renew with front differential lock removed
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 cage
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
Renew after removal
For left flange shaft
Renewing with gearbox installed
Chapter
.