Place the satellites and plastic separator into the differential housing.
If it is necessary to replace the nuts of the drive shaft mounting bolts of the axle shafts (for example, 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 installed correctly - tightly and evenly - along the entire contour of the axle gear (figure 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. Lock the pin with two pins. All internal parts must be well lubricated.
Before installing a new driven gear ring gear, the differential housing surface should be thoroughly cleaned with a wire brush (but not with sandpaper!) and cover with D6 sealant.
Heat the ring gear again (this time to 150°C) and quickly insert the differential housing into it (figure 308).
The arrow in the figure points to the chamfer of the gear ring.
After assembly, you need to maintain the press pressure for 1-2 minutes until the crown cools down.
The housing bearing and the speedometer worm gear can only be removed or installed together. In both cases, the speedometer housing must be securely fastened.
After replacing one of the parts of the gearbox housing or the differential housing bearings, it is necessary to adjust the bearing play.
Insert the outer race of the bearing into the gearbox housing from the side of the main gear pinion ring gear together with a 1.0 mm thick adjusting washer. This washer should always be 1.0 mm thick and is designated as "S1".
Insert the outer bearing race from the other side, but without the adjusting washer.
[The original information is posted on the website: VWManual.ru]
The outer and inner bearing races cannot be replaced separately.
After installing the main gear, connect both parts of the gearbox housing. Before this, install the guide pins. Tighten the bolts with a torque of 25 Nm.
Place the VW 385/17 measuring plate on the differential housing (figure 309). This plate can be replaced with a regular, well-ground one that matches the diameter of the hole for the shaft flange.
Place the VW 383/9 indicator rod against the plate and reset the indicator after the initial setting to 1.0 mm.
Move the main gear ring gear from top to bottom (by the arrow) and take readings.
The thickness of the second adjusting washer is determined by adding the obtained result and the value of 0.30 mm, which will provide preload of the bearing. If the obtained result is, for example, 1.50 mm, then the required thickness of the washer "S2" is: 1.50 mm + 0.3 mm = 1.8 mm.
There are twenty-one standard sizes of "S2" adjustment washers, with thickness differences of 0.05 mm.
Separate the two parts of the crankcase again and remove the bearing race without the adjusting washer. Insert a washer of the required thickness and reinstall the bearing race.
Attention! When replacing the toothed ring of the driven gear of the main transmission, it is not necessary to replace the secondary shaft of the gearbox. However, you should pay attention to the markings on the ring (numbers 1, 3 and 4) or its absence. The number corresponds to the number of grooves on the secondary shaft. The number (number of grooves) the secondary shaft and the ring gear must match.
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