Dismantling and assembling limited slip differential — VW

Locking effect approx. 45%

Removing and installing bearings and crown wheel => page
39-4
.

Note:

Gearboxes with limited slip differentials must be filled with special oil. See W. B. Special information No. 22 "Gearbox oils for VW and Audi".

Differential cover
Mark position with respect to housing => fig.
1
Removing => fig.
2
Pressing on => fig.
3

Thrust washer
2.3 mm thick

Inner splined plates (4)
Finding thickness of plate set => figs.
4
and
9
Use special oil when assembling parts

Outer splined plates (4)
Finding thickness of plate set => figs.
4
and
9
Use special oil when assembling parts

Differential pinion shafts
Differential pinions, small
Differential gears, large
Pressure ring
Spacer (4)
Differential housing
10 Nm
Dished washer

Fig.1
Marking position of cover and housing

Fig.2
Pulling cover off housing

Fig.3
Pressing cover on

Ensure that marks are aligned first.

Determining thickness of plate set

When new parts are installed, the thickness of the plate set must be determined. This is done by measuring the housing, cover and plate set separately.

Fig.4
Measure housing depth "a"

Example: a = 93.80 mm

Fig.5
Measure cover shoulder "b"

Example: b = 7.00 mm

Find clear depth of housing "c"

c = a - b

Example:

c = 93.80 mm - 7.00 mm

c = 86.80 mm

Fig.6
Measure thickness of plate set "d" with two 2 mm thick outer splined plates but without washers

Close vice only just enough to hold plates.

Example: d = 82.60 mm

Fig.7
Find dimension "e"

e = c - d

Example:

e = 86.80 mm - 82.60 mm

e = 4.20 mm

Dimension "e" must be 4.20 mm.

If the dimension is above or below this figure, thicker or thinner outer splined pates must be fitted.

"e" below 4.20 mm - fit thinner plates

"e" above 4.20 mm - fit thicker plates

Outer splined plates are available in thicknesses1.9 mm., 2.0 mm. and 2.1 mm.

Fig.8
After assembling, check the torque

Specified figure: 20 - 50 Nm

To measure the torque secure one side gear in the vice, using vice clamps. Fit a drive flange on the other side gear and attach an adapter (=> fig.
9
).

Fig.9
Locally manufactured adapater

1 -
Rear axle nut
2 -
Flat strip 30 x 8
3 -
Drive flange

Note:

The turning torque can be checked with the gearbox installed.

Block one wheel, place torque wrench on slotted nut of other wheel and turn wheel rapidly. The torque should be approximately as given here. Do not engage a gear while measuring the torque.