Contents: Disassembly ↓ Assembly ↓
Disassembly
Remove the speedometer drive pinion and drive coupling using a puller with jaws and a mandrel.
Press the inner races of the tapered roller bearings off the differential case by inserting the hooks of the puller into the T-shaped cutouts of the differential case and using the VW 295a mandrel.
Remove the eight hex bolts securing the final drive driven gear to the differential case.
Install the driven gear of the main transmission on two stops and press the differential box off the gear.
Remove the retaining ring from the satellite axle and press out the axle.
Remove the satellites and axle gears.
Remove the thrust collar.
Check the condition of the parts and replace damaged parts.
Assembly
Install the thrust collar onto the differential box.
Install the axle gears with threaded washers.
Install the output shafts into the differential holes and tighten them with bolts.
Install the satellites by turning them at an angle of 180°C, then turn the output shafts to bring the satellites into the mounting locations.
Finalize the position of the thrust collar and satellites.
(The original article is available at: «www.vwmanual.ru»)
Install the planet shaft and snap rings, using the dowel pins to ensure proper fit.
Install the driven gear of the main gear heated to 100°C on two stops, slide the differential box onto the gear and tighten it with two bolts. After the driven gear and differential box have cooled down, install the remaining bolts and tighten them with a torque of 5.50 kgf·m.
Press the inner race of the tapered roller bearing onto the differential case using a VW 519 guide sleeve with a diameter of 50 mm, while the ring must be preheated to 100°C.
Press on the second inner ring of the tapered roller bearing in the same manner.
Install the speedometer drive pinion and press on the drive bushing, ensuring the bushing seating depth "X" (see photo) by selecting adjusting rings with a thickness of 1.4 to 1.5 mm. The pressing depth "X" of the bushing should be 1.4 mm.
Calculation of the thickness of the adjusting rings of the rear bearings of the primary and secondary shafts
Note: This operation must be carried out very carefully, since the thickness of the adjusting washer and the sealing gasket affect the position of the main gear pinion. Measurements must be made with the outer bearing rings pressed in to the stop.
To select the thickness of the bearing adjusting rings, it is necessary to determine the following dimensions: (see picture):
- a — protrusion of the primary shaft ball bearing from the gearbox housing:
- b — protrusion of the secondary shaft tapered roller bearing from the gearbox housing;
- c — sinking of the supporting surface of the secondary shaft rear bearing in the rear cover of the gearbox;
- d — recession of the supporting surface of the rear bearing of the primary shaft in the rear cover of the gearbox;
- s — thickness of the secondary shaft rear bearing adjusting ring;
- v — thickness of the adjusting ring of the rear bearing of the primary shaft;
- e — thickness of the sealing gasket.
Use the depth gauge to determine the dimensions of "a", "b", "c" and "d".
The primary shaft bearing of some gearboxes is combined (roller-ball). In this case, a sealing gasket with a thickness of 0.40 mm is installed, and the adjustment of the axial movement of the bearings is carried out by selecting the thickness of the adjusting rings installed under the bearings of the primary and secondary shafts.
On other gearboxes, the required protrusion of the rear bearing of the primary shaft is ensured by installing a sealing gasket with a thickness of 0.30 or 0.40 mm.
The rear bearings of the primary and secondary shafts are installed with a preliminary load of 0.10 mm, ensured by compression of the sealing gasket. On a gearbox with a primary shaft ball bearing, the gasket thickness is selected based on the value of dimension "a". If dimension "a" is 0.20-0.26 mm, a gasket with a thickness of 0.30 mm should be installed. If dimension "a" is in the range of 0.27-0.42 mm, it is necessary to install a gasket with a thickness of 0.40 mm. On a gearbox with a combined primary shaft bearing, the gasket thickness is constant and equal to 0.40 mm.
Calculate the thickness of the adjusting rings using the formulas:
s=c-b+0,3,
v=d-a+0.3 (0.4).
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