Table of contents: Disassembly ↓ Assembly ↓
Disassembly
Remove the speedometer drive pinion and drive coupling using a jaw puller and a mandrel with an outer diameter of 33 mm and an inner diameter of 25 mm.
Press the inner races of the tapered roller bearings off the differential case by inserting the hooks of the puller into the T-shaped notches 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.
Install 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 thrust 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 their seats.
Finalize 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 two stops, 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 to a torque of 5.50 kgf·m.
Press the inner race of the tapered roller bearing onto the differential case using a VW 519 adjusting sleeve with a diameter of 50 mm, while the ring must be preheated to 100°C.
Press on the second inner ring of the tapered roller bearing in the same manner.
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.
