Disassembly
Remove the speedometer drive gear and drive clutch using a puller with jaws 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 from the differential box by inserting the hooks of the puller 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 retaining ring from pinion shaft and press pin out.
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 thrust washers.
Install the output shafts in the holes of the differential and tighten them with bolts.
Install the satellites, turning them at an angle of 180°C, then by turning the output shafts bring the satellites into the seat.
Finally adjust the position of the thrust holder and satellites.
Install the pinion axle and circlips, using the dowel pins to ensure proper seating.
Install the driven gear of the final drive 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 adjuster sleeve 50 mm in diameter, while the ring must be preheated to 100°C.
Press on the second tapered roller bearing inner race in the same way.
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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