Four-wheel drive - dismantling and assembling differential — VW

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009); platform code AJ5

• Special tools named: puller
• Renewed: if necessary

Don't miss

• After pulling out, check washer for damage and renew if necessary.
• Observe installation position of washer.Shoulder on inner circumference faces seal in clutch housing.
• When pulling off inner race, ensure that hooks do not bend outwards, further tightening bolt (arrow) if necessary.
• If necessary, removed sheared-off parts of spring pin from differential cage and differential pinion pin.

🔧 Engine codes this applies to

📋 Procedure

1. Clamp internal puller (B) between tapered roller bearing outer race and washer. [Note: After pulling out, check washer for damage and renew if necessary.]
2. First insert washer . [Note: Observe installation position of washer.Shoulder on inner circumference faces seal in clutch housing.]
3. Place thrust plate40 - 105 on differential cage.
4. Clamp puller, e.g. Kukko 204/2 in vicinity of flattened sides of differential cage under inner race of tapered roller bearing. [Note: When pulling off inner race, ensure that hooks do not bend outwards, further tightening bolt (arrow) if necessary.]
5. ⚠ Wear protective gloves! — Set sleeve 3301/3 from assembly tool3301 with notch (arrow) (larger inner diameter) on tapered roller bearing inner race.

6. Support gearbox housing with tube3345 directly below bearing support.
7. First drive spring pin (1) flush into differential pinion pin (2).
8. Set differential under press with spring pin (arrow) facing extension30 - 23.
9. Now press differential pinion pin out. [Note: If necessary, removed sheared-off parts of spring pin from differential cage and differential pinion pin.]
10. Lubricate one-piece thrust washer with gear oil and install.
11. Install both sun wheels and secure (e.g. with flange shaft).
12. Insert planet pinions offset 180° and pivot into position.
13. Press in differential pinion pin ((arrow A)) to first planet pinion.
14. Place threaded pieces (arrows B) in sun gears.
15. Drive differential pinion pin into final position and secure with spring pin .
16. Drive in new spring pin (arrow) flush to differential cage using a drift (1).

Other VW procedures

• Removing and installing oil filter bracket – VW · 3 torque figures
• Dismantling and assembling output shaft for 1st through 4th gears
• Topping up gear oil in bevel box · 1 torque figures
• Removing gearbox, Golf 2009 ►, with 2.0 l engine (four-wheel drive)
• Dismantling and assembling input shaft – VW · 1 torque figures
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures