Contents: Removal ↓ Disassembly (figure I:57) ↓ Preload of the secondary shaft front…↓ Differential assembly ↓ Preload of differential support…↓ Installation ↓
Removal
1. Remove the secondary shaft from the clutch housing. To do this, unscrew the bolts of the large front bearing retaining plate and remove the plate together with the outer bearing ring.
2. Remove the plastic cover from the right axle flange, release the retaining ring and remove the disc washer.
3. Remove the flange using the VW 391 tool, then remove the differential from the final drive gear.
Disassembly (figure I:57)
1. Remove the two retaining rings holding the axle shafts and pull them out of the differential housing.
2. Remove one of the retaining rings holding the satellite shaft, knock the shaft out of the housing. Remove the satellites and half-axle gears and remove the plastic thrust plate.
3. Inspect the satellites, gears, axle shafts, satellite shaft and thrust plate for wear and damage; replace worn parts if necessary.
4. Check the presenter (located on the secondary shaft) and the driven gear of the main transmission for wear or damage, replace them if necessary.
CAUTION: Replace final drive gears only in pairs.
5. If it is necessary to replace the driven gear of the main transmission, proceed as follows:
Drill pilot holes with a fine drill bit along the axis of the rivets on the side with the countersunk heads, then drill the rivets completely with a 12 mm drill bit. Knock out the rivets and press the differential housing out of the final drive pinion using a press.
6. Heat the new final drive pinion to 100°C, install two bolts as guides and press the pinion onto the differential housing (chamfer towards the body). Install the remaining bolts, lock plates and nuts from the repair kit and tighten them to the torque specified in the section "Technical data".
7. Inspect the secondary shaft bearings and differential support bearings for wear and damage; replace if necessary.
8. Install the thrust pad (VW 295 fixture) onto the differential housing and remove the bearing using a suitable puller.
9. Remove the second bearing from the differential in a similar manner. Remove both axle shaft seals from their seats using the VW681 tool and extract the outer bearing races using the VW 295 and VW 554 tools.
CAUTION: There are adjusting shims under the outer bearing races. The outer and inner races of each bearing are matched and are not interchangeable.
10. Using a puller, remove the large and small front bearings of the secondary shaft.
11. Remove the small bearing outer race from the clutch housing using the VW 510 tool and remove the adjusting shim.
CAUTION: The large bearing outer race and retainer plate must be replaced as an assembly. Do not attempt to press the outer race out of the retainer plate.
Preload of the secondary shaft front bearings
1. Heat both secondary shaft bearings to 120°C and press them onto the shaft.
2. Lubricate the bearings with transmission oil, install a 0.65 mm thick adjusting shim into the small bearing outer race seat and press the outer race into place using a suitable drift.
3. Check the condition of the lock plate bolts and replace them if necessary. Install the secondary shaft and lock plate with the outer race of the large bearing and tighten the bolts to the torque specified in the section "Technical data".
4. Screw the adapter (VW 294b/3) into one of the bolt holes of the clutch housing (figure I:62), install the heel (VW 385/17 adaptation) on the end of the secondary shaft and install a pointer indicator with a stand (VW 387 fixture) onto the adapter so that its probe rests on the heel and is recessed by 1.0 mm (on the indicator scale). Move the shaft in the longitudinal direction within the bearing clearance and note the indicator readings.
CAUTION: Do not rotate the shaft or you will get incorrect readings.
5. Add 0.65 mm to the obtained value (thickness of installed gasket) and 0.20 mm (value of required preload). Select a shim pack of this thickness (standard shim sizes are listed in the section "Technical data").
6. Remove the small bearing outer race from the clutch housing using the VW 554 tool, then remove the gasket.
7. Install a stack of adjusting shims of the correct thickness into the small bearing outer ring seat and press the outer ring in place using a mandrel.
8. Install the secondary shaft and tighten the lock plate mounting bolts to the required torque.
9. Fasten the adapter to the shaft (VW 548 fixture) and a torque meter. Measure the torque required to turn the secondary shaft and compare it with that specified in the section "Technical data" (figure I:63).
10. By increasing or decreasing the thickness of the shim pack, achieve the required torque value, then remove the secondary shaft.
Differential assembly
1. Heat the differential bearings to 120°C and press them onto the differential housing.
2. Lubricate the pinions, satellites, axle shafts and thrust plate with transmission oil and insert the thrust plate into the differential housing.
3. Install the differential pinions and axle gears inside the housing, press the pinion shaft into place and install the retaining ring.
4. Insert one of the axle shafts (with the threaded hole facing outward).
5. Press the axle shaft against the pinion shaft and the axle gear against the thrust plate and housing, and install the thicker of the two existing retaining rings onto the axle shaft (figure I:64). If the gear is jammed after installing the ring, remove the ring and install a thinner one. Repeat this operation on the other gear and axle shaft.
(The information is presented on the website: www.VWManual.ru)
Preload of differential support bearings
1. Lubricate the bearings with transmission oil, install a 1.0 mm thick shim into the differential bearing outer race seat in the clutch housing and press the outer race in place using a suitable drift.
2. Install the differential onto the clutch housing and press the outer race of the second differential bearing without a gasket into the gearbox housing using the VW 510 tool.
3. Install the transmission housing with a new gasket onto the clutch housing and secure it with five equally spaced bolts, tightening them to the torque specified in Section "Technical data".
4. Attach the dial indicator (figure I:65) to the counter (VW 387 fixture). Secure the stand with the indicator to the gearbox housing and install the VW 385/17 heel on the axle shaft.
5. Install the dial indicator probe on the heel with a 1.0 mm interference fit. Move the differential longitudinally within the bearing clearance and record the indicator readings.
CAUTION: Do not turn the differential or axle shaft, otherwise you will get incorrect indicator readings.
6. Add 0.40 mm to the resulting clearance value - the result is the required thickness of the adjusting shim. Select a shim pack of the required thickness from the range given in the section "Technical data".
7. Remove the gearbox housing, remove the outer bearing ring installed without a gasket and install a selected gasket pack under the ring (install the thickest gasket first).
8. Press the outer ring into place using the VW 295 and VW510 tools. Install the gearbox housing with the gasket onto the clutch housing and secure with five equally spaced bolts; tighten the bolts to the torque specified in the section "Technical data".
9. Screw the bolt of the VW382/3 device into one of the half-shafts. Mount the torque gauge on the half-shaft (figure I:66).
10. Fix the second axle shaft from turning and measure the torque value required to turn the differential. If the result does not fall within the limits specified in section "Technical data", change the thickness of the shim pack to obtain the required torque.
11. Remove the differential from the housing and install new axle shaft seals using the VW 194 tool.
Installation
1. Insert the differential into the clutch housing, install the secondary shaft and tighten the lock plate mounting bolts to the torque specified in the section "Technical data".
2. Proceed with gearbox assembly as described above.
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