Get FinalDriveandDifferential -> 5.1 FWD Differential, Disassembling and Assembling Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

5

Differential

⇒ “5.1 FWD Differential, Disassembling and Assembling”,

page 394

⇒ “5.2 Differential, AWD, Disassembling and Assembling”,

page 399

⇒ “5.3 Differential, Adjusting”, page 405

5.1

FWD Differential, Disassembling and

Assembling

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 - 21/7-

♦ 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-

Note

♦ Secure the transmission on the assembly stand. Refer to

⇒ “7 Transmission, Securing in Engine/Transmission Holder”, page 191 .

♦ Before installing, warm the inner race/tapered roller bearing to approximately 100 °C (212 °F) with Inductive

Heater - VAS6414- .

♦ Adjust the differential when replacing the tapered roller bearing, differential housing, transmission housing

or clutch housing. Refer to ⇒ “5.3 Differential, Adjusting”, page 405 .

394

Rep. Gr.39 - Final Drive and Differential

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

1 - Transmission Housing

2 - Shim

❑ For the differential

❑ Selecting thickness. Re‐

fer to

⇒ “5.3 Differential, Ad‐

justing”, page 405 .

3 - Outer Race/Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Outer Race/Tapered

Roller Bearing from the

Transmission Hous‐

ing”“ , page 398 .

❑ Installing. Refer to

⇒ Fig. ““Installing Outer

Race/Tapered Roller

Bearing into the Trans‐

mission Housing”“ ,

page 398 .

4 - Inner Race / Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Inner Race/Tapered

Roller Bearing”“ ,

page 397

❑ Installing. Refer to

⇒ Fig. ““Installing the In‐

ner Race/Tapered Roll‐

er Bearing”“ ,

page 397 .

5 - Differential Housing

❑ With riveted final drive

gear wheel

6 - Inner Race / Tapered Roller Bearing

❑ Removing. Refer to ⇒ Fig. ““Removing the Inner Race/Tapered Roller Bearing”“ , page 398

❑ Installing. Refer to ⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing”“ , page 398 .

7 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing”“ , page 397 .

❑ Installing. Refer to

⇒ Fig. ““Pressing Outer Race/Tapered Roller Bearing with Shim into Clutch Housing.”“ , page 397 .

8 - Washer

❑ Installed position: shoulder on inner diameter faces toward seal -item 13- ⇒ Item 13 (page 396)

❑ Allocation. Refer to the Parts Catalog.

9 - Clutch Housing

10 - Bolt

❑ 33 Nm

❑ Install with the threaded piece -item 22- ⇒ Item 22 (page 396) .

11 - Right Flange Shaft

12 - Protective Ring

❑ Pry the ring off the flange shaft with a screwdriver -item 11- ⇒ Item 11 (page 395) .

❑ Installed position: the depression points away from threaded holes in flanged shaft

5. Differential

395

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ Install the ring all the way by hand.

❑ The ring must lock into the flange shaft.

13 - Seal

❑ For the right flange shaft

❑ Allocation. Refer to the Parts Catalog.

❑ Replace when the transmission is installed. Refer to

⇒ “1.2 Right Flange Shaft Seal, Replacing”, page 370 .

14 - Flange Shaft Pressure Spring

❑ Installed behind the flange shaft

15 - Thrust Washer

❑ Installed position: the collar faces toward spring, and tab, if equipped, faces toward tapered ring

16 - Tapered Ring

❑ Installed position: ball toward the differential housing

17 - Circlip

❑ Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed

18 - Large Differential Bevel Gear

❑ Installing. Refer to ⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 399 .

19 - Differential Bevel Gear Axle

❑ Remove using a drift

❑ Installing. Refer to ⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 399 .

20 - Adapter Sleeve

❑ To secure the differential bevel gear axle

❑ Removing and installing. Refer to

⇒ Fig. ““Removing and Installing Roll Pin for Differential Bevel Gear Axle”“ , page 399 .

21 - Small Differential Bevel Gear

❑ Installing. Refer to ⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 399 .

22 - Threaded Piece

❑ Installing. Refer to ⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 399 .

23 - Thrust Washer Union

❑ Install with transmission fluid

24 - Protective Ring

❑ Pry the ring off the flange shaft with a screwdriver -item 25- ⇒ Item 25 (page 396) .

❑ Installed position: the depression points away from threaded holes in flanged 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

⇒ “1.1 Left Flange Shaft Seal, Replacing”, page 369 .

396

Rep. Gr.39 - Final Drive and Differential

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing the Outer Race/Tapered Roller Bearing from the

Clutch Housing

A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm - 21/7-

Note

Check the washer -item 8- ⇒ Item 8 (page 395) for damage after

removing it and replace if necessary.

Pressing Outer Race/Tapered Roller Bearing with Shim into

Clutch Housing.

– Install the washer beforehand.

Note

♦ Pay attention to the installed position of the shim -item 8-

⇒ Item 8 (page 395) .

♦ The collar on the inner circumference faces the seal.

Removing the Inner Race/Tapered Roller Bearing

– Before installing the puller, mount the Press Piece - Multiple

Use - 40-105- onto the differential housing.

Installing the Inner Race/Tapered Roller Bearing

5. Differential

397

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing the Inner Race/Tapered Roller Bearing

A - Puller , for example, Puller - Kukko Puller - 60-150mm Width,

200mm Length - 18/1-

B - Separating Tool 12 to 75 mm , for example, Puller - Kukko

Quick Action Separating Tool - 12-75mm - Kukko 17/1-

Installing the Inner Race/Tapered Roller Bearing

The cage with the tapered rollers must rotate easily when being

installed.

Removing the Outer Race/Tapered Roller Bearing from the

Transmission Housing

A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

B - Internal Puller 46 to 58 mm , for example, Puller - Kukko In‐

ternal - 46-56mm - 21/7-

Installing Outer Race/Tapered Roller Bearing into the Transmis‐

sion Housing

– Support the transmission housing directly under the bearing

mount using the Bearing Installer - Wheel Bearing - 3345- .

398

Rep. Gr.39 - Final Drive and Differential

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing and Installing Roll Pin for Differential Bevel Gear Axle

Removing

– Cover the inner race/tapered roller bearing in order to prevent

possible damage and entry of shavings.

– Remove the spring pin using a chisel.

Installing

– Drive into the differential housing up to the stop.

Installing the Differential Bevel Gears

– Insert thrust washer union with transmission fluid.

– Install and secure both large differential planetary gears, for

example, with a flange shaft.

– Insert the small differential planetary gears 180° offset and

pivot them into position.

– Press the differential bevel gear -arrow A- up to the first small

differential bevel gear.

– Insert threaded pieces -arrow B- into the large differential

planetary gears.

Installed position: shoulder faces the differential bevel gear

– Install the differential bevel gear axle up the end position and

secure it with a new spring pin.

5.2

Differential, AWD, Disassembling and

Assembling

Special tools and workshop equipment required

♦ Press Plate - VW402-

♦ Press Piece - Rod - VW408A-

♦ Press Piece - Rod - VW411-

♦ Press Piece - Multiple Use - VW412-

♦ Press Piece - Multiple Use - 30-23-

♦ Press Piece - Multiple Use - 40-105-

♦ Press Piece - Multiple Use - 3005-

♦ Press Piece - Bushing - 3259-

♦ Press Piece - Reverse Gear Syncro - 3296-

♦ Subframe Bushing Tool Kit - 3301-

♦ Bearing Installer - Wheel Bearing - 3345-

♦ -1- Puller - Kukko Internal - 46-56mm - 21/7-

♦ -2- Puller - Kukko Puller - 60-150mm Width, 200mm Length -

18/1-

♦ -3- Puller - Kukko Quick Action Separating Tool - 12-75mm -

17/1-

♦ -4- Puller - Kukko Counterstay - 22/2-

♦ Inductive Heater - VAS6414-

5. Differential

399

FinalDriveandDifferential -> 5.1 FWD Differential, Disassembling and Assembling for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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