Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 606
Removing the Outer Race/Tapered Roller Bearing from the
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 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 193
Groove all the way
around -arrows-
36.0 (long spring pin),
removing. Refer to
⇒ Fig. ““Spring Pin Without Sur‐
rounding Groove (Long Spring Pin),
Removing: Press Out the Differential
installing. Refer to
⇒ Fig. ““Spring Pin Without Sur‐
rounding Groove (Long Spring Pin),
no surrounding groove
Allocation, Differential Housing
The hole in the differential housing was modified due to the longer
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 the inner race/tapered roller bearing in order to prevent
possible damage and entry of shavings.
– Remove the adapter sleeve 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), In‐
stalling
– Align the hole in the differential bevel gear axle to the hole in
the differential housing.
– Install the new adapter sleeve to dimension -a- = 3.0 mm using
a mandrel -1-.
• The spring pin must not come in contact with the transmission
when the differential housing is installed.
On Some Transmissions, the Thrust Washer Union Has a Ridge
-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-.
2.3
Differential, Adjusting
Special tools and workshop equipment required
♦ Dial Gauge Holder - VW387-
♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - 30-205-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-
♦ -4- Puller - Kukko Counterstay - 22/2-
♦ Dial Gauge
A new differential adjustment is required when the following com‐
ponents have been replaced:
♦ Transmission Housing
♦ Clutch Housing
♦ Differential Housing
or the
♦ Differential tapered roller bearing
Adjustment Overview. Refer to
⇒ “3 Adjustment Overview”, page 198
.
– Press tapered roller bearing outer race into transmission hous‐
ing without shim, using Press Piece - Multiple Use - 30-205- .
Refer to
⇒ Fig. ““Installing the Outer Race/Tapered Roller Bearing Into
the Transmission Housing.”“ , page 192
.
Note
Bearing inner race and outer race of tapered roller bearing are
paired. Do not interchange them.
– Press tapered roller bearing outer race into clutch housing,
using Press Piece - Multiple Use - 30-205- . Refer to
⇒ Fig. ““Installing Outer Race/Tapered Roller Bearing Into the
.
– Insert differential into clutch housing.
– Position the transmission housing and tighten the 5 bolts to
the tightening specification.
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