Table of contents: Disassembly ↓ Assembly ↓
Disassembly
Remove the speedometer drive pinion and drive sleeve using a jaw puller and drift.
Press the inner races of the tapered roller bearings off the differential case by inserting the hooks of the puller into the T-shaped cutouts of the differential case and using the VW 295a mandrel.
Remove the eight hex bolts securing the final drive driven gear to the differential case.
Place the driven gear of the main transmission on two stops and press the differential box off the gear.
Remove the retaining ring from the satellite axle and press out the axle.
Remove the satellites and axle gears.
Remove the thrust collar.
Check the condition of the parts and replace damaged parts.
Assembly
Install the thrust collar onto the differential box.
Install the axle gears with threaded washers.
Install the output shafts into the differential holes and tighten them with bolts.
Install the satellites by turning them at an angle of 180°C, then by turning the output shafts, bring the satellites into the mounting places.
Make final adjustments to the position of the thrust collar and satellites.
Install the planet shaft and snap rings using the dowel pins to ensure proper fit.
Install the driven gear of the main gear 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 down, install the remaining bolts and tighten them with a torque of 5.50 kgf·m.
Press the inner race of the tapered roller bearing onto the differential case using a VW 519 guide sleeve with a diameter of 50 mm, making sure that the ring is preheated to 100°C.
Press on the second inner race of the tapered roller bearing in the same manner.
Installing the speedometer drive gear (the circle shows the seating depth "X" of the drive bushing)
Install the speedometer drive pinion and press on the drive bushing, ensuring the bushing seating depth "X" (see photo) by selecting adjusting rings with a thickness of 1.4 to 1.5 mm. The pressing depth "X" of the bushing should be 1.4 mm.