Disassembly
Remove the speedometer drive gear and drive clutch using a puller and mandrel.
Press the tapered roller bearing inner races off the differential case. by inserting the puller hooks into the T-shaped cutouts of the differential box and using the VW 295a mandrel.
Remove the eight hex bolts securing the final drive gear to the differential case.
Install the final drive gear on the two stops and press the differential box off the gear.
Remove the circlip from the satellite shaft and press out the shaft.
Remove satellites and side gears.
Remove the retaining clip.
Check the condition of parts and replace damaged parts.
Assembly
Install the thrust clip on the differential box.
Install side gears with threaded washers.
Install the output shafts in the holes of the differential and tighten them with bolts.
Install the satellites by turning them at an angle of 180°C, then turn the output shafts into the seats.
Finally adjust the position of the thrust cage and satellites.
Install the pinion shaft and circlips using the dowel pins to ensure proper seating.
Install the driven gear of the final drive heated to 100°C on the bottom of the stop, slide the differential box onto the gear and tighten it with two bolts. After the driven gear and differential box have cooled, install the remaining bolts and tighten them to a torque of 5.50 kgf·m.
Press the inner ring of the tapered roller bearing onto the differential box using a VW 519 guide bush with a diameter of 50 mm, while the ring must be preheated to 100°C.
Press on the second tapered roller bearing inner race in the same way.
Installing the running gear of the speedometer drive (the circle shows the planting depth «X» drive bushings)
Install the speedometer drive gear and press on the drive bushing, ensuring the seating depth «X» (see photo) bushings by selection of adjusting rings with a thickness of 1.4 to 1.5 mm. Pressing depth «X» bushings should be 1.4 mm.
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