Repairing cover for Torsen differential, removing and installing Torsen differential — VW
Repairing cover for Torsen differential, removing and installing Torsen differential on VW: factory workshop procedure.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📋 Procedure
ℹ️ Torque figures below come verbatim from workshop data — always cross-check against your vehicle's factory manual before final tightening.
VW
Passat
1997
Passat Variant
1997
Power transmission
5-speed manual gearbox 01A, all-wheel drive
Edition
03.2011
Repairing cover for Torsen differential, removing and installing Torsen differential
Special tools and workshop equipment required
Pressure plate
VW 401
Pressure plate
VW 402
Press tool
VW 407
Press tool
VW 412
Guide pin
VW 439
Thrust piece
3002
Tube
VW 416 B
Drift sleeve
40 - 21
Tube
VW 519
Tube
2040
Multipurpose tool
VW 771
Adapter
VW 771/15
3
Splitter
Kukko 17/2
Gearbox cover
Compression spring
Front needle bearing
Removing
Fig.
Installation position
Fig.
Pressing in
Fig.
Torsen differential
Do not dismantle.
Remove after removing flange shaft
Fig.
.
Renew if damaged
Pressing in
Fig.
Rear needle bearing
Removing
Fig.
Installation position
Fig.
Pressing in
Fig.
Ball bearing
For Torsen differential.
Pressing off
Fig.
Pressing on
Fig.
Retaining ring
Retaining ring
Removing and installing together with flange shaft
Fig.
.
Ball bearing
For flange shaft.
Removing
Fig.
Pressing in
Fig.
Cover
Retaining ring
Cover plate
Removing
Fig.
O-ring
Always renew
Insert with grease.
Torx screw, 25 Nm
Seal
Pull out with
extractor lever
VW 681
.
Driving in
Fig.
Balance weight
Retaining ring
Torx screw, 35 Nm
Self-locking
Always renew
Flange shaft
Removing and installing
Fig.
Remove cap.
Remove retaining ring
A
.
Screw M8 bolt into threaded hole of sealing cap
B
.
Pull out sealing cap
B
with bolt.
Removing and installing flange shaft
Removing
Spread retaining ring while pulling out flange shaft.
Installing
When the flange shaft is inserted, the retaining ring must be inserted at the same time.
The retaining ring must seat in the base of the groove.
Pressing out Torsen differential
Pass
thrust piece
3002
through hole
arrow
and position directly on Torsen differential.
Pressing ball bearing off Torsen differential
A
Splitter, 22 … 115 mm
, e.g.
Kukko 17/2
Pressing ball bearing onto Torsen differential
Pressing out ball bearing for flange shaft
Pressing in ball bearing for flange shaft
Pulling out needle roller bearing
A
Internal puller, 22…28 mm
, e.g.
Kukko 21/4
Both needle bearings in Torsen differential are pulled out using same internal puller.
Front needle bearing installation position
Dimension
a
= 32.5 mm
Rear needle bearing installation position
Dimension
a
= 14 mm
Pressing in needle bearing
Both needle bearings in Torsen differential are pressed in with same special tool.
Pressing in Torsen differential
Driving in seal
Installation position:
2 mm below surface of cover
TorqFix answers live for your specific car — tell it the engine code and it serves the matching sequence, torque figures and wiring for that exact variant.
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.