Volkswagen Golf Variant / Jetta. Manual - part 539

 

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Volkswagen Golf Variant / Jetta. Manual - part 539

 

 

-arrows-.

– Remove the driveshaft from the flange shaft.
– Tie up the driveshaft as high as possible. Do not damage the

paint on the driveshaft.

– Place the Drip Tray under the transmission.
– Remove bolts for flange shaft, by installing two bolts into the

flange and counter-holding flange shaft using a tire iron.

– Remove the flange shaft with the pressure spring.

– Remove the flange seal using the Slide Hammer - VW771-

and the Slide Hammer Set - Hook - VW771/37- .

1.2.2

Installing

– Install the seal all the way in without tilting it.
– Fill the space between the sealing/dust lip halfway with Seal‐

ing Grease - G 052 128 A1- .

– Install the flange shaft.
– Fasten flange shaft with countersunk screw and tighten to 25

Nm.

– Attach the drive axle to the flange shaft. Refer to ⇒  Suspen‐

sion, Wheels, Steering; Rep. Gr.  40 ; Drive Axles, Removing

and Installing .

– If equipped install the drive shaft heat shield -arrows-. Refer

Overview and Servicing; Drive Axle Heat Shield .

– Check the transmission fluid level. Refer to

⇒ “5 Transmission Fluid, Checking”, page 111

 .

50 ; Noise Insulation .

172

Differential

⇒ “2.1 Differential, Disassembling and Assembling”, page 173
⇒ “2.2 Differential, Adjusting”, page 178
⇒ “2.3 Differential Shim S2, Selecting”, page 179

2.1

Differential, Disassembling and Assem‐

bling

Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 31.5mm - VW418A-
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Multiple Use - VW455-
♦ Press Piece - Multiple Use Spacer Sleeve - VW472/2-
♦ Press Piece - Multiple Use - VW510-
♦ Press Piece - Multiple Use - 30-14-
♦ Press Piece - Front Control Arm - 2040-
♦ Press Piece - Output Shaft Gear/Final Drive Gear - 3002-
♦ Flywheel Retainer - 3067-
♦ Press Piece - Bushing - 3259-
♦ Bearing Installer - Wheel Bearing - 3345-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-
♦ Puller - Kukko Internal - 46-56mm - 21/7-
♦ Puller - Kukko Counterstay - 22/2-
♦ Press Piece - Multiple Use - 30-205-
♦ Bearing Installer - Differential Bearing - 40-21-
♦ Torque Wrench 5-50Nm - VAG1331-
♦ Puller - Taper Roller Bearing - Adapter 3 - VAG1582/3-
♦ Inductive Heater - VAS6414-

Note

To install, heat the bearing inner races/tapered roller bearing to approximately 100 °C (212 °F) with Inductive

Heater - VAS6414- . Wear protective gloves.

Replace both tapered roller bearings together.

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

or clutch housing. Refer to 

⇒ “2.2 Differential, Adjusting”, page 178

 .

2. Differential    

173

❑ 25 Nm
❑ Install with the threaded

piece -item 8-

⇒ Item 8 (page 174)

2 - Right Flange Shaft
3 - Flange Shaft Pressure

Spring

❑ Installed behind the

flange shafts

4 - Thrust Washer

❑ Installed position: shoul‐

der faces the pressure

spring

5 - Tapered Ring

❑ Installed position: ball

toward the differential

housing

6 - Circlip

❑ Holds the tapered ring,

the thrust washer and

the pressure spring

when the flange shaft is

removed

7 - Large Differential Bevel

Gear

❑ Installing. Refer to

⇒ Fig. ““Installing the

Differential Bevel

Gears”“ , page 178

 .

8 - Threaded Piece

❑ Installing. Refer to

⇒ Fig. ““Installing the

Differential Bevel Gears”“ , page 178

 .

9 - Differential Bevel Gear Axle

❑ shear off roll pin -item 18- 

⇒ Item 18 (page 175)

 to remove. Refer to

⇒ Fig. ““Removing the Differential Bevel Gear Axle”“ , page 178

❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 178

 .

10 - Small Differential Bevel Gear

❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 178

 .

11 - Thrust Washer Union

❑ Install with transmission fluid

12 - Left Flange Shaft
13 - Seal

❑ For the left flange shaft
❑ Replace with transmission installed. Refer to 

⇒ “1.1 Left Flange Shaft Seal, Replacing”, page 170

14 - Shim S1

❑ For the differential
❑ always 1 mm thick
❑ Shim S1 is deleted as of production date 12/04/2006. Refer to

⇒ Fig. ““Shim S1 for the outer race/tapered roller bearing is deleted as of production date 04/12/2006.”“ ,

page 179

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❑ Outer race/tapered roller bearing seat adapted in transmission housing
❑ Allocation. Refer to the Parts Catalog.

15 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the outer race/tapered roller bearing from the transmission housing”“ , page 176

❑ Installing. Refer to

⇒ Fig. ““Installing the outer race/tapered roller bearing into the transmission housing.”“ , page 176

16 - Bearing Inner Race/Taper Roller Bearing

❑ Removing. Refer to 

⇒ Fig. ““Removing the Bearing Inner Race/Taper Roller Bearing”“ , page 176

❑ Installing. Refer to 

⇒ Fig. ““Installing the Bearing Inner Race/Taper Roller Bearing”“ , page 176

17 - Differential Housing

❑ With final drive gear wheel

18 - Adapter Sleeve

❑ To secure the differential bevel gear axle
❑ sheared off at removal. Refer to 

⇒ Fig. ““Removing the Differential Bevel Gear Axle”“ , page 178

19 - Bearing Inner Race/Taper Roller Bearing

❑ Removing. Refer to 

⇒ Fig. ““Removing the bearing inner race/taper roller bearing”“ , page 177

❑ Installing. Refer to 

⇒ Fig. ““Installing the Bearing Inner Race/Taper Roller Bearing”“ , page 177

20 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Pressing tapered roller bearing outer race -A- out from clutch housing”“ , page 177

❑ Installing. Refer to

⇒ Fig. ““Installing outer race/tapered roller bearing into the clutch housing”“ , page 177

21 - Shim S2

❑ For the differential
❑ Selecting thickness. Refer to 

⇒ “2.2 Differential, Adjusting”, page 178

 .

22 - Seal

❑ For the right flange shaft
❑ replace with transmission installed 

⇒ “1.2 Right Flange Shaft Seal, Replacing”, page 171

23 - Transmission Housing

❑ Servicing. Refer to 

⇒ “7 Transmission Housing and Clutch Housing, Servicing”, page 127

 .

❑ Shim S1 is deleted as of production date 12/04/2006

⇒ Fig. ““Shim S1 for the outer race/tapered roller bearing is deleted as of production date 04/12/2006.”“ ,

page 179

❑ Outer race/tapered roller bear seat adapted
❑ Allocation. Refer to the Parts Catalog.

24 - Clutch Housing

❑ Servicing. Refer to 

⇒ “7 Transmission Housing and Clutch Housing, Servicing”, page 127

 .

2. Differential    

175

 

 

 

 

 

 

 

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