Dismantling and assembling differential: Gearbox codes: GEQ, GSE, GEW, GSG — VW

Dismantling and assembling differential: Gearbox codes FNT, FLU, GAH => Page
39-17
.

Special tools and workshop equipment required

VW 401 Thrust plate
VW 402 Thrust plate

Special tools and workshop equipment required

VW 408 A Press tool
VW 412 Press tool
VW 418 A Tube
30-205 Pressure plate

Special tools and workshop equipment required

VW 455 Fitting sleeve
VW 472/2 Spacer sleeve
40-21 Drive sleeve
30-14 Escape hose
2040 Tube
3002 Press piece

Special tools and workshop equipment required

3067 Counterhold
3259 Hose
V.A.G 1582 Taper roller bearing extractor
V.A.G 1582/3 Grip
1 - Kukko 21/7 Internal extractor
4 - Kukko 22/2 Counterhold

Notes:

Heat taper roller bearing inner race to 100 °C before installing.
Always renew both taper roller bearings together as a set.
If differential housing, gearbox housing or clutch housing taper roller bearings are renewed adjust differential => page
39-47
.

Countersunk bolt, 25 Nm
Bolt into threaded piece (item
8
)

Right-hand flanged shaft
Spring for flange shaft
Installed behind flange shafts.

Thrust washer
Installation position: the collar facing the spring

Tapered ring
Installation position: Taper towards differential housing.

Retaining ring
Hold the position of the conical ring, the thrust washer and the pressure spring when the flanged shaft has been removed

Sun wheel
Installing => fig.
8
.

Threaded piece
Installing => fig.
8
.

Differential pinion pin
To dismantle, cut the tensioning sleeve (item
18
) => fig.
7
Installing => fig.
8
.

Planet pinion
Installing => fig.
8
.

One-piece thrust washer
Coat with gearbox oil when installing

Left-hand flanged shaft
Oil seal for left-hand flanged shaft
Renewing with gearbox installed => page
39-1
.

Adjusting washer S1
For differential.
Always 1 mm thick

Taper roller bearing outer race
Pulling out => fig.
1
.
Pressing in => fig.
2
.

Taper roller bearing inner race
Pulling off => fig.
3
.
Pressing on => fig.
4
.

Differential cage
With riveted final drive gear wheel
Is paired with output shaft, only renew as a set

Spring pin
To secure the cog shaft
Cut to dismantle=> fig.
7

Taper roller bearing inner race
Pulling off => fig.
3
.
Pressing on => fig.
4
.

Taper roller bearing outer race
Pressing out => fig.
5
.
Pressing in => fig.
6
.

Adjusting washer S2
For differential.
Determining thickness => page
39-47
.

Oil seal for right-hand flanged shaft
Renewing with gearbox installed => page
39-1
.

Gearbox housing
Repairing => page
34-79

Clutch housing
Repairing => page
34-79

Fig.1
Pulling taper roller bearing outer race out from gearbox housing

A - Counterhold, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

Fig.2
Pressing taper roller bearing outer race into gearbox housing

Fit adjusting washer 1, always 1 mm thick, below external ring.
Support the gearbox housing , placing the tube 3259 directly below the socket housing.

Fig.3
Pressing off taper roller bearing inner race

Before fitting the extractor, place the spacer VW 472/2 and tool 3002 on the housing of the differential.

Note:

Both taper roller bearing inner races are pulled off the differential housing in the same way.

Fig.4
Pressing on taper roller bearing inner races

Support the opposite side of the internal ring with sleeve VW 455.
The step of the fitting sleeve -VW455- shows to the differential housing.

Note:

Both taper roller bearing inner races are pressed on the differential housing in the same way.

Fig.5
Unclip the conical roller bearing external ring from the clutch housing -A-

B - Internal puller 46...58 mm, e.g. Kukko 21/7

When doing this tension internal puller behind the taper roller bearing outer race.

Fig.6
Pressing taper roller bearing outer race into clutch housing

Fig.7
Unclip cog shaft.

When unclipping, the support sleeve has to be cut.

Remove the remaining piece of the sleeve from the differential housing.

Fig.8
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 wheels offset 180°and pivot into position.
Push differential pinion shaft (arrow -A-) in until first planet wheel.

Place threaded pieces (arrows -B-) in sun gears.
Drive differential pinion shaft into final position and secure with spring pin.