Differential (VW Passat B4)

To disassemble, press out the outer bearing rings from the clutch housing and gearbox housing sockets. Remove the adjusting ring from the clutch housing socket.

Using a puller or press, press the inner races of the tapered roller bearings off the differential case.

Using a 12 mm drill, drill out the heads of the rivets securing the driven gear of the main transmission from the milled side of the gear and knock out the rivets.

Using a drift, sink the spring pin securing the satellite axle into the axle (Fig. 4-36) and press out the satellite axle. Knock out the spring pin from the satellite axle. Remove the axle gears, satellites and thrust washers. Press out the driven gear of the main transmission using a press.



To assemble the differential, heat the driven gear of the main transmission and press the gear onto the differential box. Center it with two bolts, screw in and tighten the special bolts for fastening the driven gear of the main transmission with spacer plates.

Install the thrust washers, lubricate them with transmission oil, install the satellites, press in the satellite axles and install the spring pin for securing the axle, pressing it flush with the surface of the differential case. Install the axle gears in the differential case (Fig. 4-37), then turn them into place. Press the inner rings of the roller bearings onto the differential case with a press.





Adjust the differential bearing preload as follows.

Press the outer rings of the differential bearings into the sockets of the clutch housing and gearbox housing.

Note: The inner and outer bearing rings are matched in pairs and cannot be separated.