Get FinalDriveandDifferential -> 5.2 Differential, AWD, 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

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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

♦ -3- Puller - Kukko 2-Arm w/Side Clamp, 100mm Width, 100mm

Length - 204/2-

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- .

♦ Replace both tapered roller bearings together.

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

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

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 404 .

❑ Installing. Refer to

⇒ Fig. ““Installing Outer

Race/Tapered Roller

Bearing into the Trans‐

mission Housing”“ ,

page 404 .

4 - Inner Race / Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Inner Race/Tapered

Roller Bearing”“ ,

page 403

❑ Installing. Refer to

⇒ Fig. ““Heat the Inner

Race/Tapered Roller

Bearing and Press On

It”“ , page 403 .

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 403

❑ Installing. Refer to ⇒ Fig. ““Installing the Inner Race/Tapered Roller Bearing”“ , page 403 .

7 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing”“ , page 402 .

400

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

❑ Installing. Refer to

⇒ Fig. ““Pressing Outer Race/Tapered Roller Bearing with Shim Into Clutch Housing.”“ , page 402 .

8 - Washer

❑ Installed position: the collar on the inner circumference faces the seal.

❑ Allocation. Refer to the Parts Catalog.

9 - Clutch Housing

10 - Seal

❑ Installed in the manual transmission, between the manual transmission and the bevel box

❑ Replace with transmission installed. Refer to

⇒ “2.3 Bevel Box Seal, Replacing, with Manual Transmission Installed”, page 375

❑ Remove using the Puller - Crankshaft/Power Steering Seal - 2 - T20143/2- or Puller - Seal Lever - VW681-

❑ Can be driven in to the stop with a Seal Installer - Crankshaft - T40007- in a disassembled transmission.

11 - Seal

❑ For the right flange shaft

❑ The left and right diameters are different

❑ Replace with manual transmission installed with bevel box. Refer to

⇒ “2.2 Right Flange Shaft Seal, Replacing”, page 373 .

12 - Hex Bolt -item 17- ⇒ Item 17 (page 235)

13 - Bolt

❑ 33 Nm

❑ Install with the threaded piece -item 24- ⇒ Item 24 (page 402) .

14 - Right Flange Shaft

❑ Removing and installing. Refer to ⇒ “2.2 Right Flange Shaft Seal, Replacing”, page 373 .

15 - Seal

❑ Remove to replace needle bearing (polygon bearing -item 16- ⇒ Item 16 (page 401) )

16 - Needle Bearing (Polygon Bearing)

❑ Replacing. Refer to

⇒ “3.5 Needle Bearing (polygon bearing) on Right Flange Shaft and Seal on Right Flange Shaft, Re‐

placing”, page 387 .

17 - Circlip

❑ Replace after removing

❑ For the needle bearing (polygon bearing)

❑ Insert in the surrounding flange shaft groove

18 - Bevel Box

❑ Seals, flange shaft bearing and output flange bearing inside the bevel box. Refer to

⇒ “3 Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box”,

page 377 .

19 - Seal

❑ Installed in the bevel box between the bevel box and the manual transmission

❑ Replace with bevel box removed. Refer to

⇒ “3.2 Gasket on Bevel Box between Manual Transmission and Bevel Box, Replacing”, page 380

20 - Large Differential Bevel Gear

❑ Installing. Refer to ⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 405 .

21 - Differential Bevel Gear Axle

❑ Removing. Refer to ⇒ Fig. ““Removing the Differential Bevel Gear Axle and Spring Pin”“ , page 404 .

❑ Installing. Refer to ⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 405 .

22 - Adapter Sleeve

❑ To secure the differential bevel gear axle

❑ Removing. Refer to ⇒ Fig. ““Removing the Differential Bevel Gear Axle and Spring Pin”“ , page 404 .

5. Differential

401

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

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ Drive new roll pin in flush. Refer to ⇒ Fig. ““Roll Pin, Installing”“ , page 405

23 - Small Differential Bevel Gear

❑ Removing and installing. Refer to ⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 405 .

24 - Threaded Piece

❑ Installing. Refer to ⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 405 .

25 - Thrust Washer Union

❑ Install with transmission fluid

26 - Circlip

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

27 - Tapered Ring

❑ With grooves for the thrust washer

❑ Installed position: ball toward the differential housing

28 - Thrust Washer

❑ Installed position: collar towards spring, tab toward tapered ring

29 - Left Flange Shaft Spring

❑ Installed behind left flange shaft

30 - Left Flange Shaft

31 - Seal

❑ For the left flange shaft

❑ The left and right diameters are different

❑ Replace when the transmission is installed. Refer to

⇒ “2.1 Left Flange Shaft Seal, Replacing”, page 373 .

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-

– Tension the internal puller -B- between the outer ring/tapered

roller bearing and washer.

Note

Check the washer -item 8- ⇒ Item 8 (page 401) for damage after

removing it and replace if necessary.

Pressing Outer Race/Tapered Roller Bearing with Shim Into

Clutch Housing.

– Install the washer -item 8- ⇒ Item 8 (page 401) beforehand.

Note

♦ Pay attention to the installed position of the shim.

♦ The collar on the inner circumference faces the seal.

402

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 Inner Race/Tapered Roller Bearing

– Place the Press Piece - Multiple Use - 40-105- on the differ‐

ential housing.

– Tension the Puller , for example, Puller - Kukko 2-Arm w/Side

Clamp, 100mm Width, 100mm Length - 204/2- near the flat‐

tened sides of the differential housing under the inner race/

tapered roller bearing.

Note

When pulling off inner race, make sure that the hooks do not bend

outward; if necessary, re-tighten bolt -arrow-.

Heat the Inner Race/Tapered Roller Bearing and Press On It

WARNING

Wear safety gloves.

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 - 17/1-

Installing the Inner Race/Tapered Roller Bearing

WARNING

Wear safety gloves.

– Place the Subframe Bushing Tool Kit - Assembly Tool 3 -

3301/3- on the Subframe Bushing Tool Kit - 3301- with the

notch -arrow- (larger inner diameter) on inner race/tapered

roller bearing.

5. Differential

403

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

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- .

Removing the Differential Bevel Gear Axle and Spring Pin

– First drive roll pin -1- flush into differential bevel gear axle

-2-.

– Mount the differential under the press with the adapter sleeve

-arrow- facing the Press Piece - Multiple Use - 30-23- .

– Then remove the differential bevel gear axle.

Note

If necessary, remove the sheared parts of the adapter sleeve from

the differential bevel box housing and remove the differential bev‐

el gear axle.

404

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

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 axle -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. Refer to

⇒ Fig. ““Roll Pin, Installing”“ , page 405 .

Roll Pin, Installing

– Drive new roll pin -arrow- flush into differential bevel gear axle

with a drift -1-.

5.3

Differential, Adjusting

⇒ “5.3.1 Determining the Shim”, page 406

Special tools and workshop equipment required

♦ Measuring Set - Magnetic Plate - 50mm - VW385/17-

♦ Dial Gauge Holder - VW387-

♦ Press Plate - VW402-

♦ Press Piece - Rod - VW408A-

♦ Press Piece - Multiple Use - 3005-

♦ Press Piece - Bushing - 3259-

♦ Bearing Installer - Wheel Bearing - 3345-

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

♦ Puller - Kukko Counterstay - 22/2-

♦ Dial Indicator - VAS6080A-

♦ 30 mm dial gauge extension

A new differential adjustment is required when the following com‐

ponents have been replaced:

♦ Transmission Housing

♦ Clutch Housing

♦ Differential housing or

♦ Differential tapered roller bearing

5. Differential

405

FinalDriveandDifferential -> 5.2 Differential, AWD, Disassembling and Assembling for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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