Installing differential
1. If necessary, insert adjusting shims and outer bearing rings in transmission housing and differential cover. The adjusting shims sit under the outer bearing rings.
2. Insert final drive in transmission housing.
3. Coat new toroidal sealing ring on lid with oil and place onto lid.
4. Position cover for final drive.
Scheme 49
5. Screw in cover screws -1, 2 and 3- and tighten by hand. (Scheme 45)
6. Screw in cover screws in the following order -1 to 12- and tighten. (Scheme 45)
| Location | Explanation | Type | Basic value | Tolerance 1 | Tolerance 2 |
|---|---|---|---|---|---|
| Cover screws | Tightening torque | 23 (17 ftlb.) Nm |
1. Top up oil for final drive and perform all assembly work described. > 399055 Changing oil for final drive
2. Retaining device P 9624/1 must then be removed from cross member.
3. Fit restraining cables to cross member.
| Location | Explanation | Type | Basic value | Tolerance 1 | Tolerance 2 |
|---|---|---|---|---|---|
| Restraining cable | Fastening nut between restraining cable and cross member | Tightening torque | 23 (17 ftlb.) Nm |
4. Install support plate. Refer to 42 14 19 Removing and installing support plate - as of MY 2005 (All Models) .
5. Install right wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
6. Lower the vehicle.
Designation Type Number Explanation engine support special tool P 9589 engine and gear support VW-tool VW 540
1. Remove transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2005 (All Models) .
2. Tighten the transmission using engine support P 9589 or engine and gear support VW 540 at the assembly support.
3. Drain transmission oil. Refer to 34 01 55 Changing transmission oil - as of MY 2005 (Boxster, Boxster RHD) .
Scheme 50
| No. | Designation | Qty. |
|---|---|---|
| 1 | Flanged shaft | 2 |
| 2 | Circlip | 2 |
| 3 | Torx screw | 10 |
| 4 | Cover for final drive | 1 |
| 5 | Differential | 1 |
| 6 | Speedometer-drive gear | 1 |
| 7 | Tachometer sensor | 1 |
| 8 | O-ring | 1 |
| 9 | Transmission housing | 1 |
Scheme 51
1. Remove flanged shaft. To do this, place a chisel or spacer -A- under the flanged shaft and pull out the flanged shaft by turning the screw -B-. (Scheme 49)
2. Unscrew Torx screws -3- between cover and housing and tap cover off using a rubber hammer if necessary. (Scheme 48)
3. Remove differential.
Note. The flanged shafts are installed with polygonal bearings. The rough running of these bearings when the flanged shafts are not installed does not indicate that the bearings are faulty. The polygonal bearings can be replaced only with the flanged shaft.
| No. | Designation | Qty. | Fitting |
|---|---|---|---|
| 1 | Flanged shaft | 2 | Grease circlip and drive in using a rubber hammer |
| 2 | Circlip | 2 | Always replace |
| 3 | Torx screw | 10 | > Tightening torque: 25 (19 ftlb.) Nm |
| 4 | Cover for final drive | 1 | Seal with Loctite 574 |
| 5 | Differential | 1 | |
| 6 | Speedometer-drive gear | 1 | |
| 7 | Tachometer sensor | 1 | |
| 8 | O-ring | 1 | Always replace, lightly oil |
| 9 | Transmission housing | 1 |
1. Insert differential in transmission housing.
2. Position cover for differential on transmission housing and screw in screws.
> Tightening torque: 25 (19 ftlb.) Nm
Scheme 52
3. Replace circlip for the halfshaft flange. To do this, clamp the flange in the vice with a hexagon-head bolt -B- and press out the circlip with the new circlip -A-. see scheme 26
4. Grease circlip for easier fitting.
5. Drive halfshaft flange into transmission using a rubber hammer.
1. Fill with transmission oil. Refer to 34 01 55 Changing transmission oil - as of MY 2005 (Boxster, Boxster RHD) .
2. Remove transmission from assembly support.
3. Install transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2005 (All Models) .
Designation Type Number Explanation pressure piece VW-tool 2050 pressure piece commercially available tool p 263 drive-in mandrel commercially available tool vw 295 pressure piece commercially available tool vw 472/1 thrust washer commercially available tool vw 511
Scheme 53
1. Remove differential. > 390919 Removing and installing differential - section on "Removing"
Scheme 54
| No. | Designation | Qty. | Removal |
|---|---|---|---|
| 1 | Speedometer-drive gear | 1 | |
| 2 | Taper roller bearing inner ring (1) | 1 | Pull off using a commercially available two-arm puller and the pressure piece p 263 . |
| 3 | Taper roller bearing inner ring (1) | Pull off using a commercially available two-arm puller and the pressure piece p 263 . | |
| 4 | Crown wheel screw | 10 | |
| 5 | Crown wheel (1) | 1 | Force off with a mandrel through the threaded bores. |
| 6 | Roll pin | 1 | |
| 7 | Axle | 1 | |
| 8 | Differential bevel gear (small) | 2 | |
| 9 | Differential bevel gear (large) | 2 | |
| 10 | Thrust washer assembly | 1 | |
| 11 | Differential housing (1) | 1 | |
| 12 | Taper roller bearing outer ring | 1 | Drive out using a suitable aluminum or copper mandrel (diameter of 6...8 mm). |
| 13 | Adjusting shim S 1 | X | Note the thickness for re-installation. |
| 14 | Cover for final drive (1) | 1 | |
| 15 | Taper roller bearing outer ring | 1 | Drive out using a suitable aluminum or copper mandrel (diameter of 6...8 mm). |
| 16 | Adjusting shim | X | Note the thickness for re-installation. |
| 17 | Transmission housing (1) | 1 | |
| (1) If these parts are replaced, re-adjustment is necessary. |
| (1) | If these parts are replaced, re-adjustment is necessary. |
Scheme 55
1. Force crown wheel off differential housing with a punch.