Put satellites and a plastic separator into the differential case.
If it is necessary to replace the nuts of the bolts of the drive shafts of the axle shafts (e.g. in case of damage to their threads), it is necessary to knock out the old nuts from the outside and insert new ones from the inside in their place. Pay attention to the fact that the nuts are correctly - tightly and evenly - installed along the entire contour of the side gear (pic. 307).
Insert the drive shafts into the gears. Insert one satellite through the hole and turn it 1800. Insert the second satellite opposite the first. Install the satellites on the same axis with the holes in the differential housing for the pin and install the pin. Secure your finger with two pins. All internal parts must be well lubricated.
Before installing a new driven gear ring, the surface of the differential housing should be thoroughly cleaned with a wire brush (but not sandpaper!) and coat with sealant D6.
Heat the crown again (this time up to 150°C) and quickly insert the differential housing into it (pic. 308).
The arrow in the figure points to the chamfer of the ring gear.
After assembly, you need to hold the pressure of the press for 1-2 minutes until the crown cools down.
The housing bearing and speedometer worm gear can only be removed or installed together. In both cases, the speedometer housing must be well secured.
After replacing one of the parts of the gearbox housing or differential housing bearings, it is necessary to adjust the play of the bearings.
Into the gearbox housing, insert the outer race of the bearing from the side of the ring gear of the main gear together with the shim 1.0 mm thick. This washer should always be 1.0 mm thick and is designated as «S1».
Insert the outer race of the bearing from the other side, but without the shim.
The outer and inner races of the bearings must not be replaced separately.
After installing the main gear, connect both parts of the gearbox housing. Before doing this, install the guide pins. Tighten the bolts to a torque of 25 Nm.
Place a measuring plate VW 385/17 on the differential case (pic. 309). This plate can be replaced with a conventional one, well ground and corresponding to the diameter of the hole for the shaft flange.
Attach the indicator rod VW 383/9 to the plate and zero the indicator after the initial setting of 1.0 mm.
Move the main gear ring gear from top to bottom (in the direction of the arrow) and take readings.
The thickness of the second shim is determined by adding the result obtained and the value of 0.30 mm, which will provide the bearing preload. If the result obtained is, for example, 1.50 mm, then the desired washer thickness «S2» it turns out: 1.50 mm + 0.3 mm \u003d 1.8 mm.
There are shims «S2» twenty-one standard sizes, with a difference in thickness through 0.05 mm.
Separate both parts of the crankcase again and remove the bearing race without the shim. Insert a washer of the required thickness and reinstall the bearing race.
Attention! When replacing the ring gear of the driven gear of the final drive, it is not necessary to replace the output shaft of the gearbox. However, you should pay attention to the markings on the crown (numbers 1, 3 and 4) or its absence. The number corresponds to the number of grooves on the secondary shaft. Number (number of grooves) at the output shaft and the ring gear must match.
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