Volkswagen Golf Variant / Jetta. Manual - part 201

⇒ Fig. ““Spring Pin without Surrounding Groove (Long Spring Pin), Removing: Press Out the Differential

Bevel Gear Axle”“ , page 268

❑ Long tension sleeve: installing. Refer to

⇒ Fig. ““Spring Pin without Surrounding Groove (Long Spring Pin), Installing”“ , page 268

23 - Small Differential Bevel Gear

❑ Installing. Refer to

⇒ Fig. ““Installing the Differential Planetary Gears and Differential Bevel Gear Axle”“ , page 269

 .

24 - Large Differential Bevel Gear

❑ Installing. Refer to

⇒ Fig. ““Installing the Differential Planetary Gears and Differential Bevel Gear Axle”“ , page 269

 .

Removing the Outer Race/Tapered Roller Bearing from the

Clutch Housing
– Remove the right flange shaft seal or the sleeve for the right

seal/flange shaft beforehand.

Installing Outer Race/Tapered Roller Bearing into the Clutch

Housing
There is no adjusting shim on the side of the clutch housing.

Removing the Bearing Inner Race/Taper Roller Bearing
– Mount the Press Piece - Multiple Use - 40 - 105- on the differ‐

ential housing before removing the puller.

Note

Both tapered roller bearing inner races are pulled off from the dif‐

ferential housing in the same way.

266

Note

Both tapered roller bearing inner races are pressed on from the

differential housing in the same way.

Removing the Outer Race/Tapered Roller Bearing from the

Transmission Housing
A - Counter Support , for example, Puller - Kukko Counterstay -

Kukko 22/2-
B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm -Kukko 21/7-

Installing the Outer Race/Tapered Roller Bearing into the Trans‐

mission Housing.
– Install the adjusting shim under the outer race.
– Support the transmission housing with the Bearing Installer -

Wheel Bearing - 3144- directly under the bearing mount.

Differentiating the Spring Pins

Dimension “a” mm

Identifying feature

28.5 (short tension sleeve),

Removing and installing. Refer to

⇒ Fig. ““Spring Pin with Surrounding

Groove (Short Spring Pin): Remov‐

ing and Installing”“ , page 268

Groove all the way

around -arrows-

36.0 (long spring pin),

Removing. Refer to

⇒ Fig. ““Spring Pin without Surround‐

ing Groove (Long Spring Pin), Re‐

moving: Press Out the Differential

Bevel Gear Axle”“ , page 268

 ,

Installing. Refer to

⇒ Fig. ““Spring Pin without Surround‐

ing Groove (Long Spring Pin), Instal‐

ling”“ , page 268

no surrounding groove

3. Differential    

267

spring pin.

Hole

Spring pin length (mm)

-A-

28.5 (short spring pin)

-A and B-

36.0 (long spring pin)

Spring Pin with Surrounding Groove (Short Spring Pin): Remov‐

ing and Installing
Removing
– Cover inner race/tapered roller bearing in order to prevent

possible damage and entry of shavings.

– Remove the spring pin using a chisel.
Installing
– Drive into the differential housing up to the stop.

Spring Pin without Surrounding Groove (Long Spring Pin), Re‐

moving: Press Out the Differential Bevel Gear Axle
Spring pin is sheared off when it is removed.
– Drive remaining part of roller pin out of differential housing.

Spring Pin without Surrounding Groove (Long Spring Pin), Instal‐

ling
– Align the hole in the differential bevel gear axle to the hole in

the differential housing.

– Install the new spring pin to dimension -a- = 3.0 mm using a

drift -1-.

• The spring pin must not come in contact with the transmission

when the differential housing is installed.

268

-A-.
Also, the differential housing has a groove -B- all the way around

it.
– Insert thrust washer union with transmission fluid.
– Install the thrust washer union so that it fits into the groove

-B- in the differential housing.

Installing the Differential Planetary Gears and Differential Bevel

Gear Axle
– Insert thrust washer union with transmission fluid.
– Install and secure both large differential planetary gears, for

example, with a flange shaft.

– Insert the small differential planetary gears 180° offset and

pivot them into position.

– Press the differential bevel gear axle -arrow A- up to the first

small differential bevel gear.

– Insert threaded pieces -arrow B- into the large differential

planetary gears.

Installed position: shoulder faces the differential bevel gear
– Install the differential bevel gear axle up the end position and

secure it with a new spring pin.

Installed Position: Tapered Ring Thrust Washer -1-
The collar -arrow- faces the pressure spring -B-.
Some transmissions are not equipped with ridges -A-.
The ridges -A- face the tapered ring -1-.

3.2

Differential, Adjusting

⇒ “3.2.1 Determining the Shim”, page 270

Special tools and workshop equipment required
♦ Measuring Set - Magnetic Plate - 50mm - VW 385/17-
♦ Dial Gauge Holder - VW387-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - 30 - 205-

3. Differential    

269