Disassembling and Assembling

Differential, Disassembling And Assembling

Overview

^ If tapered roller bearings, differential housing, final dove cover, ring gear and pinion or transmission housing is replaced, the differential must be adjusted. Adjustments





1. Sun gear
^ Removing and installing
2. Threaded piece
^ Install before inserting shaft for bevel gears
3. Planet pinion
^ Removing and installing
4. Planet pinion
^ Removing and installing
5. Circlip
^ For output shaft
6. Sun gear
^ Removing and installing
7. One-piece thrust washer
^ Coat with transmission oil when installing
8. Shim S1
^ Determining thickness; adjusting ring gear; Adjustments
9. Tapered roller bearing outer race
^ Remove with driver 3138
^ Pressing in; see Fig. 1
10, Tapered roller bearing inner race
^ Pulling off; see Fig. 2
^ Pressing on; see Fig. 3
11. Ribbed combi bolt
^ Tighten to 80 Nm (44 ft. lbs.) and turn an additional 60°
- Replace each time its removed
12. Shaft for beveled gears
- Drive out with a drift
^ When driving in, do not damage one-piece thrust washer
13. Differential housing
14. Ring gear
^ Number of teeth; Refer to Specifications.
- Install heated; see Fig. 4
^ Is mated with output shaft, only replace as a set
- Drive off differential with a drift
15. Tapered roller bearing inner race
^ Pulling off; see Fig. 2
^ Pressing on; see Fig. 3
16. Tapered roller bearing outer race
- Drive out with drift
^ Pulling in; see Fig. 5
17. Shim S2
^ Determining thickness adjusting ring gear; Adjustments
18. Output shaft for drive flange






Fig. 1 Tapered roller bearing outer race, pressing in






Fig. 2 Tapered roller bearing inner race, pulling off
- Place press piece 40-105 on differential housing.







Fig. 3 Tapered roller bearing inner race, pressing on
- Heat inner race to approx. 100°C (212°F).
^ Temperature can be checked with tool VAG 1558.
- Press tapered roller bearing inner race on differential housing, to stop.






Fig. 4 Heated ring gear, installing
- Heat ring gear to approx. 100° C (212° F).
^ Temperature can be checked with tool VAG 1558.
- Install ring gear over centering pins -A- (local manufacturer) on differential housing.






Fig. 5 Tapered roller bearing outer race, pressing into transmission housing
I -Tapered roller bearing outer race, press in transmission housing with press plate 30-205.
II - Connect press piece of puller 3046 to spindle and pull in outer race.


Differential, disassembling and assembling

Disassembling
- Remove bolts on ring gear and drive ring gear off differential housing with a drift.
- Drive small planet pinion axis shaft out.
- Remove threaded piece.
- Remove 3 differential beveled gears from differential housing.
- Take drive flange circlip off output shaft.
- Remove 4th differential beveled gear and output shaft.
- Remove one piece thrust washer.

Assembling
- Lubricate one-piece thrust washer with transmission oil and install.





- Insert output shaft-2- in differential housing -1-.
- Observe installation position: the end with two bearing positions (arrows) faces toward differential.
- Place sun gear on drive shaft and secure with circlip.





- Insert flanged shaft -1-, as an assembly aid, into differential housing -2-.
- Secure sun gear to flanged shaft using bolt and threaded piece.
- Insert planet gears turned through 180� and pivot into position on flanged shafts.





- Drive shaft -A-for bevel gears in carefully, ensure one piece thrust washer is not damaged.
- Install heated ring gear, Fig. 4.
- Remove flange from differential housing.