Volkswagen Golf Variant / Jetta. Manual - part 307

ential housing.

– Tension the Puller , for example, Puller - Kukko 2-Arm w/Side

Clamp, 100mm Width, 100mm Length - 204/2- near the flat‐

tened sides of the differential housing under the inner race/

tapered roller bearing.

Note

When pulling off inner race, make sure that the hooks do not bend

outward; if necessary, re-tighten bolt -arrow-.

Heat the Inner Race/Tapered Roller Bearing and Press On It

WARNING

Wear safety gloves.

Removing the Inner Race/Tapered Roller Bearing
A - Puller , for example, Puller - Kukko Puller - 60-150mm Width,

200mm Length - 18/1-
B - Separating Tool 12 to 75 mm , for example, Puller - Kukko

Quick Action Separating Tool - 12-75mm - 17/1-

Installing the Inner Race/Tapered Roller Bearing

WARNING

Wear safety gloves.

– Place the Subframe Bushing Tool Kit - Assembly Tool 3 -

3301/3- on the Subframe Bushing Tool Kit - 3301- with the

notch -arrow- (larger inner diameter) on inner race/tapered

roller bearing.

5. Differential    

403

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

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

ternal - 46-56mm - 21/7-

Installing Outer Race/Tapered Roller Bearing into the Transmis‐

sion Housing
– Support the transmission housing directly under the bearing

mount using the Bearing Installer - Wheel Bearing - 3345- .

Removing the Differential Bevel Gear Axle and Spring Pin
– First drive roll pin -1- flush into differential bevel gear axle

-2-.

– Mount the differential under the press with the adapter sleeve

-arrow- facing the Press Piece - Multiple Use - 30-23- .

– Then remove the differential bevel gear axle.

Note

If necessary, remove the sheared parts of the adapter sleeve from

the differential bevel box housing and remove the differential bev‐

el gear axle.

404

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. Refer to

⇒ Fig. ““Roll Pin, Installing”“ , page 405

 .

Roll Pin, Installing
– Drive new roll pin -arrow- flush into differential bevel gear axle

with a drift -1-.

5.3

Differential, Adjusting

⇒ “5.3.1 Determining the Shim”, page 406

Special tools and workshop equipment required
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Dial Gauge Holder - VW387-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - 3005-
♦ Press Piece - Bushing - 3259-
♦ Bearing Installer - Wheel Bearing - 3345-
♦ Puller - Kukko Internal - 46-56mm - 21/7-
♦ Puller - Kukko Counterstay - 22/2-
♦ Dial Indicator - VAS6080A-
♦ 30 mm dial gauge extension
A new differential adjustment is required when the following com‐

ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Differential housing or
♦ Differential tapered roller bearing

5. Differential    

405

⇒ “4 Overview - Adjustment”, page 393

 .

– Pressing outer race/tapered roller bearing with shim into clutch

housing.

Note

♦

Pay attention to the installed position of the shim.

♦

The collar on the inner circumference faces the seal.

– Press the outer race/tapered roller bearing without the shim

into transmission housing.

– Insert differential into clutch housing.
– Position the transmission housing and tighten the 5 bolts to

the tightening specification -item 13- 

⇒ Item 13 (page 230)

 and

-item 14- 

⇒ Item 14 (page 230)

 .

– Push the differential toward the clutch housing and rotate eight

times at the same time.

– Press differential in direction of transmission housing and ro‐

tate eight times at the same time.

– Attach the gauge to the transmission housing and set it to “0”

with 1 mm of pretension.

A - 30 mm dial gauge extension
– Move the differential up and down and read the play on the

dial gauge and note it (example: 0.70 mm).

5.3.1

Determining the Shim

The specified bearing pre-load is obtained by adding a constant

pre-load figure of 0.25 mm to the reading obtained.
Example

Measured value

0.70 mm

+ Preload (constant value)

0.25 mm

Adjusting shim thickness =

0.95 mm

– Remove the transmission housing.

406