Differential, disassembling and assembling Volkswagen Jetta IV

Differential, disassembling and assembling

Special tools and equipment required

Scheme 111

1. VW 402 Thrust plate
2. VW 408 A Press tool
3. VW 411 Press tool
4. 30-205 Thrust plate

1. 40-21 Press tool
2. V.A.G 1582 Tapered roller bearing puller

Scheme 112

1. VW 191
2. VW 472/1 Thrust piece
3. VW 472/2 Thrust piece
4. VW 792 Thrust piece

1. 3347 Assembly tool
2. 2010

Scheme 113

1. VW 433 Thrust piece
2. V.A.G 1582/6 Grip
3. V.A.G 1582/6A Grip
4. V.A.G 1582/11 Grip

1. Kukko 21/7 Internal puller
2. Kukko 22/2 Counter-support

Scheme 114

1. V.A.G 1582/3 Clamping ring

Note. For transmissions produced from 04.98, the tool for removing the tapered roller bearings in the final drive and differential is VAG 1582/8

Scheme 115

1. 30-555 Thrust piece

Note. Heat tapered roller bearing inner race to 100 ° C before pressing on. Heat adjusting ring for tapered roller bearing to 100 ° C before pressing in tapered roller bearing outer race.

Scheme 116

1 - Differential housing with riveted gear for final drive

1. Final drive gear is riveted onto differential housing and then machined
2. If differential or final drive gear is damaged, replace differential housing together with riveted final drive gear
3. Number of teeth on final drive gear. Refer to «Code letters, application, ratios, equipment»(ref-255022-S31801598012007052300000)
4. Differential housings differ depending on diameter of tapered roller bearings

2 - Output shaft/drive flange

1. Removing and installing. Refer to «Differential, removing and installing»(ref-255022-S01271707232007052300000)

3 - Tapered roller bearing inner race

1. There are different sizes of tapered roller bearings. Installed location can vary
2. Pulling off. See «Pulling off tapered roller bearing inner race»(ref-255022-S15581595202007062800000) and «Pulling out tapered roller bearing outer race»(ref-255022-S12738065482007062800000)
3. Pressing on. See «Pressing on tapered roller bearing inner race»(ref-255022-S20915440502007062800000) (with equal sized bearings on both sides)
4. Pressing on. See «Pressing in tapered roller bearing outer race»(ref-255022-S09707037162007062800000)

4 - Tapered roller bearing outer race

1. Remove and install only when adjusting ring is heated
2. Drive out with drift
3. Pressing in. See «Pressing in tapered roller bearing outer race»(ref-255022-S06396498432007062800000)

5 - Bearing body for tapered roller bearing

1. There are different types of bearing body
2. Removing and installing. Refer to Removing and installing differential, «Differential, removing and installing»(ref-255022-S01271707232007052300000)
3. Pulling off tapered roller bearing/inner race. Refer to «Pulling off tapered roller bearing inner race»(ref-255022-S02564680012007062800000)
4. Pressing on. See «Pressing in tapered roller bearing outer race»(ref-255022-S17255415332007062800000)

1. Pressing on. See «Pressing on tapered roller bearing inner race»(ref-255022-S19093975082007062800000)

6 - O-ring

1. Always replace

7 - O-ring

1. Always replace

8 - Adjusting ring for tapered roller bearing

1. Removing and installing. Refer to «Differential, removing and installing»(ref-255022-S01271707232007052300000) ; Differential, removing and installing

9 - Output shaft/drive flange

1. Removing and installing. Refer to «Differential, removing and installing»(ref-255022-S01271707232007052300000) ; Differential, removing and installing

10 - Tapered roller bearing outer race

1. Remove and install only when adjusting ring is heated
2. Drive out with drift
3. Pressing in. See «Pressing in tapered roller bearing outer race»(ref-255022-S06396498432007062800000)

11 - Tapered roller bearing inner race

1. There are different sizes of tapered roller bearings. Installed location can vary
2. Pulling off. Refer to «Pulling off tapered roller bearing inner race»(ref-255022-S15581595202007062800000) (with equal sized bearings on both sides)
3. Pressing on. See «Pressing on tapered roller bearing inner race»(ref-255022-S20915440502007062800000)
4. Inserting. See «Inserting differential bevel gears»(ref-255022-S05464430752007062800000)

12 - Driver bushing

1. Drive off together with speedometer drive gear item -13
2. Drive on with drift

13 - Speedometer drive gear

1. Drive out with a drift
2. Fit on together with driver bushing item -12

14 - One-piece thrust washer

1. Place into differential cage before inserting bevel gears

15 - Small bevel gears

16 - Large bevel gears

1. Inserting. See «Inserting differential bevel gears»(ref-255022-S05464430752007062800000)

17 - Circlip

18 - Bevel gear shaft

1. Drive out with a drift
2. When driving in, do not damage one-piece thrust washer

19 - Spring pin

1. For securing bevel gear shaft
2. Removing and installing. See «Removing and installing spring pin for bevel gear shaft»(ref-255022-S16861128502007062800000)

Scheme 117

Use adapter V.A.G 1582/6A for larger bearings

1. Place press piece 30-555 on differential housing.

Note. For transmissions produced from 04.98, the tool for removing the tapered roller bearings in the final drive and differential is VAG 1582/8

Scheme 118

Scheme 119

Scheme 120

Scheme 121

1. Insert one-piece thrust washer with gear oil.
2. Insert small bevel gears, drive in shaft and secure with spring pin.
3. Insert large bevel gears offset 180 ° and swivel in direction of arrow.

Scheme 122

1. With adjusting ring or bearing body heated, insert outer race and press home up to stop.

Scheme 123

A - Kukko 22/2 counter-support

B - Kukko 21/7 internal puller

Scheme 124

Scheme 125

1. Place press piece VW 433 on bearing body.

Scheme 126

Scheme 127

1. Length of spring pin: 28.5 mm

Removing

1. Pull out spring pin with side cutting pliers.

Installing

1. Drive in spring pin up to stop.