Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ Heat taper roller bearing inner race to
  100 °C before installing.
• ◆ Always renew both taper roller bearings together as a set.
• ◆ If taper roller bearings are renewed adjust differential .

• Gearbox housing
• Shim S1
• ◆ For differential
• ◆ Always 1 mm thick
• Taper roller bearing outer race
• ◆ Pressing out => Fig.1
• ◆ Pressing in => Fig.2
• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig.4

• Final drive gear wheel
• ◆ Removing and installing
  => Page 39-17
• ◆ Ensure correct ratio (number of teeth) => Page 00-3
• One-piece thrust washer
• ◆ Coat with gearbox oil when installing
• Sun wheel
• ◆ Installing => Fig.5
• Threaded piece
• Planet pinion
• ◆ Installing => Fig.5
• Planet pinion axis shaft
• ◆ Knock out with drift
• Speedometer drive wheel
• ◆ Lever out with screwdriver

• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on with VW 454
• Taper roller bearing outer race
• ◆ Pressing out => Fig.7
• ◆ Pressing in => Fig.8
• Shim S2
• ◆ For differential
• ◆ Determining thickness => Page 39-23
• Clutch housing
• Angle piece
• ◆ Secures planet pinion axis shaft on gearboxes where final drive gear wheel is rivetted
• ◆ Secured by rivets (Item19 )

• Spring pin
• ◆ For securing planet pinion axis shaft on gearboxes with bonded gear wheel
• Differential housing
• ◆ When renewing: Observe adjustment overview => Page 39-22
• Rivet
• ◆ As produced
• ◆ Drilling out => Fig.9
• ◆ Installing gear wheel with bolts => Fig.10
• Hexagon nut, 70 Nm
• Final drive gear, rivetted or bolted
• ◆ Rivetted in production
• ◆ Bolted => Fig.10

→ Fig.1     Pressing out taper roller bearing outer race

→ Fig.2     Pressing in taper roller bearing outer race

→ Fig.3     Pulling off taper roller bearing inner race

• ‒ Before fitting the extractor position press piece 30-11 on differential housing.

Note:

Both both taper roller bearing inner races are pulled off the differential housing in the same way.

→ Fig.4     Pressing on taper roller bearing inner race

• ‒ Heat inner ring before pressing on to approx. 100° C.

→ Fig.5     Installing differential bevel wheels

• ‒ Lubricate one piece thrust washer with gearbox oil and install.
• ‒ Install both sun wheels and secure (e.g. with flanged shaft).
• ‒ Insert a planet pinion and turned through 180°.
• ‒ Insert 2nd planet pinion exactly opposite first. Swing planet pinions into position. Push axis for planet pinions in up to 1st gear.
• ‒ Insert threaded pieces ensuring they are seated correctly.
• ‒ Drive planet pinion shaft into final position and secure.

→ Fig.6     Pressing on taper roller bearing inner race

• ‒ Heat inner ring before pressing on to approx. 100°C.

→ Fig.7     Pressing out taper roller bearing outer race

→ Fig.8     Pressing in taper roller bearing outer race

→ Fig.9     Drilling off rivet heads

• ‒ Drill out rivet heads with 12 mm drill from countersunk side
  and knock-out with drift.

Note:

Clean differential before and after drilling, protect taper roller bearing from drillings.

→ Fig.10     Assemble gear wheel and differential housing using special bolts, plates and nuts