Differential, Disassembling and Assembling Overview

Special tools and equipment
- VW295 needle bearing drift
- VW401 thrust plate
- VW402 thrust plate
- VW407 punch
- VW408A punch
- VW412 thrust disc
- VW442 thrust pad
- 40-21 sleeve
- 40-105 thrust piece
- 2050 thrust plate
- 3138 drift
- VAG 1582 tapered roller bearing puller with VAG1582/6 attachment
- Kukko 44/2 two arm puller

Notes:
- Observe general repair instructions, Refer to Manual Transmission/Transaxle, Service and Repair.
- Replace both tapered roller bearings together. If possible use same manufacturer.
- Adjustments are required when replacing components marked with 1), Refer to List of Adjustments.

1. Cover for final drive 1)
2. O-ring
- Always replace
- Lubricate with oil before installing
3. Final drive housing 1)
4. Shim S2
5. Small tapered roller bearing outer race 1)
- Removing refer to Fig. 1
- Pressing in refer to Fig.2
6. Small tapered roller bearing inner race 1)
- Removing refer to Fig. 3
- Installing refer to Fig.4
7. Bolt
- Always replace
- Lightly tighten bolts, then tighten diagonally to correct torque
- 60 Nm (44 ft. lbs.) + 1/8 turn (45°)
- Allocation, Refer to Parts Supplier.
8. Differential - housing 1)
9. Ring gear 1)
- Matched with pinion shaft (in ring gear and pinion set)
- Select correct version according to code letters, Refer to Parts Supplier.
- Remove differential housing using mandrel refer to Fig. 9
- Installing on differential housing refer to Fig. 10
10. Roll pin
- For securing differential bevel gear shaft for differential bevel gears
- Drive in flush
11. Large tapered roller bearing inner race 1)
- Removing refer to Fig. 5
- Installing refer to Fig. 6
12. Large tapered roller bearing outer race 1)
- Removing refer to Fig. 7
- Installing refer to Fig.8
13. Shim S1
14. Threaded piece
15. Differential - bevel gears, large
- Installing refer to Fig. 11
- Adjusting refer to Fig. 12
16. Differential - bevel gears, small
- Installing refer to Fig. 11
17. Differential - bevel gear shaft
- Drive out using drift
- Carefully drive in, so that thrust washer is not damaged
- Secure with roll pin (item -10-)
18. Shim
- Re-determining thickness refer to Fig. 12
19. Thrust washer
- Check for cracks