Volkswagen Golf Variant / Jetta. Manual - part 306

 

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Volkswagen Golf Variant / Jetta. Manual - part 306

 

 

possible damage and entry of shavings.

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

Installing the Differential Bevel Gears
– 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 -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.

5.2

Differential, AWD, Disassembling and

Assembling

Special tools and workshop equipment required
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Rod - VW411-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - Multiple Use - 30-23-
♦ Press Piece - Multiple Use - 40-105-
♦ Press Piece - Multiple Use - 3005-
♦ Press Piece - Bushing - 3259-
♦ Press Piece - Reverse Gear Syncro - 3296-
♦ Subframe Bushing Tool Kit - 3301-
♦ Bearing Installer - Wheel Bearing - 3345-
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-
♦ -2- Puller - Kukko Puller - 60-150mm Width, 200mm Length -

18/1-

♦ -3- Puller - Kukko Quick Action Separating Tool - 12-75mm -

17/1-

♦ -4- Puller - Kukko Counterstay - 22/2-
♦ Inductive Heater - VAS6414-

5. Differential    

399

Length - 204/2-

Note

Secure the transmission on the assembly stand. Refer to

⇒ “7 Transmission, Securing in Engine/Transmission Holder”, page 191

 .

Before installing, warm the inner race/tapered roller bearing to approximately 100 °C (212 °F) with Inductive

Heater - VAS6414- .

Replace both tapered roller bearings together.

Adjust the differential when replacing the tapered roller bearing, differential housing, transmission housing

or clutch housing. Refer to 

⇒ “5.3 Differential, Adjusting”, page 405

 .

1 - Transmission Housing
2 - Shim

❑ For the differential
❑ Selecting thickness. Re‐

fer to

⇒ “5.3 Differential, Ad‐

justing”, page 405

 .

3 - Outer Race/Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Outer Race/Tapered

Roller Bearing from the

Transmission Hous‐

ing”“ , page 404

 .

❑ Installing. Refer to

⇒ Fig. ““Installing Outer

Race/Tapered Roller

Bearing into the Trans‐

mission Housing”“ ,

page 404

 .

4 - Inner Race / Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Inner Race/Tapered

Roller Bearing”“ ,

page 403

❑ Installing. Refer to

⇒ Fig. ““Heat the Inner

Race/Tapered Roller

Bearing and Press On

It”“ , page 403

 .

5 - Differential Housing

❑ With riveted final drive

gear wheel

6 - Inner Race / Tapered Roller Bearing

❑ Removing. Refer to 

⇒ Fig. ““Removing the Inner Race/Tapered Roller Bearing”“ , page 403

❑ Installing. Refer to 

⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing”“ , page 403

 .

7 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing”“ , page 402

 .

400

⇒ Fig. ““Pressing Outer Race/Tapered Roller Bearing with Shim Into Clutch Housing.”“ , page 402

 .

8 - Washer

❑ Installed position: the collar on the inner circumference faces the seal.
❑ Allocation. Refer to the Parts Catalog.

9 - Clutch Housing
10 - Seal

❑ Installed in the manual transmission, between the manual transmission and the bevel box
❑ Replace with transmission installed. Refer to

⇒ “2.3 Bevel Box Seal, Replacing, with Manual Transmission Installed”, page 375

❑ Remove using the Puller - Crankshaft/Power Steering Seal - 2 - T20143/2- or Puller - Seal Lever - VW681-
❑ Can be driven in to the stop with a Seal Installer - Crankshaft - T40007- in a disassembled transmission.

11 - Seal

❑ For the right flange shaft
❑ The left and right diameters are different
❑ Replace with manual transmission installed with bevel box. Refer to

⇒ “2.2 Right Flange Shaft Seal, Replacing”, page 373

 .

12 - Hex Bolt -item 17- 

⇒ Item 17 (page 235)

13 - Bolt

❑ 33 Nm
❑ Install with the threaded piece -item 24- 

⇒ Item 24 (page 402)

 .

14 - Right Flange Shaft

❑ Removing and installing. Refer to 

⇒ “2.2 Right Flange Shaft Seal, Replacing”, page 373

 .

15 - Seal

❑ Remove to replace needle bearing (polygon bearing -item 16- 

⇒ Item 16 (page 401)

 )

16 - Needle Bearing (Polygon Bearing)

❑ Replacing. Refer to

⇒ “3.5 Needle Bearing (polygon bearing) on Right Flange Shaft and Seal on Right Flange Shaft, Re‐

placing”, page 387

 .

17 - Circlip

❑ Replace after removing
❑ For the needle bearing (polygon bearing)
❑ Insert in the surrounding flange shaft groove

18 - Bevel Box

❑ Seals, flange shaft bearing and output flange bearing inside the bevel box. Refer to

⇒ “3 Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box”,

page 377

 .

19 - Seal

❑ Installed in the bevel box between the bevel box and the manual transmission
❑ Replace with bevel box removed. Refer to

⇒ “3.2 Gasket on Bevel Box between Manual Transmission and Bevel Box, Replacing”, page 380

20 - Large Differential Bevel Gear

❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 405

 .

21 - Differential Bevel Gear Axle

❑ Removing. Refer to 

⇒ Fig. ““Removing the Differential Bevel Gear Axle and Spring Pin”“ , page 404

 .

❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 405

 .

22 - Adapter Sleeve

❑ To secure the differential bevel gear axle
❑ Removing. Refer to 

⇒ Fig. ““Removing the Differential Bevel Gear Axle and Spring Pin”“ , page 404

 .

5. Differential    

401

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

23 - Small Differential Bevel Gear

❑ Removing and installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 405

 .

24 - Threaded Piece

❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 405

 .

25 - Thrust Washer Union

❑ Install with transmission fluid

26 - Circlip

❑ Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed

27 - Tapered Ring

❑ With grooves for the thrust washer
❑ Installed position: ball toward the differential housing

28 - Thrust Washer

❑ Installed position: collar towards spring, tab toward tapered ring

29 - Left Flange Shaft Spring

❑ Installed behind left flange shaft

30 - Left Flange Shaft
31 - Seal

❑ For the left flange shaft
❑ The left and right diameters are different
❑ Replace when the transmission is installed. Refer to

⇒ “2.1 Left Flange Shaft Seal, Replacing”, page 373

 .

Removing the Outer Race/Tapered Roller Bearing from the

Clutch 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-
– Tension the internal puller -B- between the outer ring/tapered

roller bearing and washer.

Note

Check the washer -item 8- 

⇒ Item 8 (page 401)

 for damage after

removing it and replace if necessary.

Pressing Outer Race/Tapered Roller Bearing with Shim Into

Clutch Housing.
– Install the washer -item 8- 

⇒ Item 8 (page 401)

 beforehand.

Note

Pay attention to the installed position of the shim.

The collar on the inner circumference faces the seal.

402

 

 

 

 

 

 

 

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