Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 535
2
Differential
⇒ “2.1 Overview - Differential”, page 212
⇒ “2.2 Differential, Disassembling and Assembling”, page 214
⇒ “2.3 Differential, Adjusting”, page 218
2.1
Overview - Differential
Note
♦
Secure the transmission on the assembly stand. Refer to
⇒ “7 Securing on Engine and Transmission Holder”, page 141
.
♦
To install, warm the inner races/tapered roller bearing to approximately 100 °C (212 °F) with Inductive Heater
- VAS6414- .
♦
Replace both tapered roller bearings together.
♦
Adjust the differential when replacing tapered roller bearing, differential housing, transmission housing or
clutch housing. Refer to
⇒ “2.3 Differential, Adjusting”, page 218
.
♦
The items -18 to 23- are no longer individual replacement parts on some transmissions. Refer to the Parts
Catalog.
1 - Transmission Housing
2 - Shim
❑ For the differential
❑ Selecting thickness. Re‐
fer to
3 - Outer Race/Tapered Roller
Bearing
❑ Removing. Refer to
❑ Installing. Refer to
4 - Inner Race / Tapered Roller
Bearing
❑ Removing. Refer to
❑ Installing. Refer to
5 - Differential
❑ With final drive gear
wheel
6 - Inner Race / Tapered Roller Bearing
⇒ Fig. ““Removing the Inner Race/Tapered Roller Bearing”“ , page 216
❑ Installing. Refer to
⇒ Fig. ““Heat the Inner Race/Tapered Roller Bearing and Press On It”“ , page 216
7 - Outer Race/Tapered Roller Bearing
❑ Removing. Refer to
⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing”“ , page 215
❑ Installing. Refer to
⇒ Fig. ““Pressing Outer Race/Tapered Roller Bearing with Shim into Clutch Housing”“ , page 215
8 - Washer
❑ Installation position: The collar on the inner diameter faces the right flange shaft seal.
❑ Allocation. Refer to the Parts Catalog.
9 - Clutch Housing
10 - Seal
❑ For the right flange shaft
❑ Allocation. Refer to the Parts Catalog.
❑ Replace when the transmission is installed. Refer to
⇒ “1.3 Right Seal, Replacing”, page 209
.
11 - Bolt
❑ 33 Nm
❑ Install with the threaded piece -Item 22-
12 - Right Flange Shaft
13 - Ring
❑ Pry the ring off the right flange shaft with a screwdriver
❑ Installed position: The depression faces away from threaded holes in flange shaft.
❑ Install the ring all the way by hand. Refer to
⇒ “2.1 Overview - Differential”, page 212
❑ The ring must lock into the flange shaft.
14 - Flange Shaft Pressure Spring
❑ Installed behind the flange shaft
15 - Thrust Washer
❑ Installed position: Collar to compression spring, braces (if installed) to tapered ring
16 - Tapered Ring
❑ Installed position: differential housing taper
17 - Locking Ring
❑ Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed
18 - Large Differential Bevel Gear
❑ Availability. Refer to the Parts Catalog.
❑ Installing. Refer to
⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 217
19 - Differential Taper Axle
❑ Availability. Refer to the Parts Catalog.
❑ Remove using a drift
❑ Installing. Refer to
⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 217
20 - Adapter Sleeve
❑ Availability. Refer to the Parts Catalog.
❑ To secure the differential bevel gear axle
❑ Removing. Refer to
⇒ Fig. ““Removing the Spring Pin for the Differential Bevel Gear Axle”“ , page 217
❑ Installing. Refer to
⇒ Fig. ““Installing the Spring Pin for the Differential Bevel Gear Axle”“ , page 218
21 - Small Differential Bevel Gear
❑ Availability. Refer to the Parts Catalog.
❑ Installing. Refer to
⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 217
.
22 - Threaded Piece
❑ Availability. Refer to the Parts Catalog.
❑ Installing. Refer to
⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 217
.
23 - Thrust Washer Union
❑ Availability. Refer to the Parts Catalog.
❑ Install with transmission fluid
24 - Ring
❑ Pry the ring off the left flange shaft with a screwdriver
❑ Installed position: The depression faces away from threaded holes in flange shaft.
❑ Install the ring all the way by hand.
❑ The ring must lock into the flange shaft.
25 - Left Flange Shaft
26 - Seal
❑ For the left flange shaft
❑ Allocation. Refer to the Parts Catalog.
❑ Replace when the transmission is installed. Refer to
⇒ “1.2 Left Seal, Replacing”, page 207
2.2
Differential, Disassembling and Assem‐
bling
Special tools and workshop equipment required
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Press Piece - Multiple Use - 40-105-
♦ Press Piece - Multiple Use - 3005-
♦ Press Piece - Bushing - 3259-
♦ Press Piece - Reverse Gear Syncro - 3296-
♦ Bearing Installer - Wheel Bearing - 3345-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 6A - VAG1582/6A-
♦ Puller - Kukko Internal - 46-56mm - 21/07-
♦ Puller - Kukko Puller - 60-150mm Width, 200mm Length -
18/1-
♦ Puller - Kukko Quick Action Separating Tool - 12-75mm - 17/1-
♦ Puller - Kukko Counterstay - 22/2-
♦ Inductive Heater - VAS6414-
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ Seal - Right Flange Shaft
Removing the Outer Race/Tapered Roller Bearing from the
Clutch Housing
A - Counter Support , for example, -22/2-
B - Internal Puller 46 to 58 mm , for example, -21/7-
Note
♦
Tension the -21/7- -B- between the outer race/tapered roller
bearing and shim tightly -Item 8-
.
♦
Check the shim for damage after removing it. Replace, if nec‐
essary.
♦
Instead of the -21/7- the -21/8- can also be used.
Pressing Outer Race/Tapered Roller Bearing with Shim into
Clutch Housing
– Install the old washer -Item 8-
clutch housing.
• Installed position of shim: The collar on the inner circumfer‐
ence faces the seal.
Removing the Inner Race/Tapered Roller Bearing
– Before installing the puller, mount the -40-105- onto the dif‐
ferential housing.
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