Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 535

2

Differential

⇒ “2.1 Overview - Differential”, page 212
⇒ “2.2 Differential, Disassembling and Assembling”, page 214
⇒ “2.3 Differential, Adjusting”, page 218

2.1

Overview - Differential

Note

♦

Secure the transmission on the assembly stand. Refer to

⇒ “7 Securing on Engine and Transmission Holder”, page 141

 .

♦

To install, warm the inner races/tapered roller bearing to approximately 100 °C (212 °F) with Inductive Heater

- VAS6414- .

♦

Replace both tapered roller bearings together.

♦

Adjust the differential when replacing tapered roller bearing, differential housing, transmission housing or

clutch housing. Refer to 

⇒ “2.3 Differential, Adjusting”, page 218

 .

♦

The items -18 to 23- are no longer individual replacement parts on some transmissions. Refer to the Parts

Catalog.

1 - Transmission Housing
2 - Shim

❑ For the differential
❑ Selecting thickness. Re‐

fer to

⇒ “2.3 Differential, Ad‐

justing”, page 218

 .

3 - Outer Race/Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Outer Race/Tapered

Roller Bearing from the

Transmission Hous‐

ing”“ , page 216

❑ Installing. Refer to

⇒ Fig. ““Installing Outer

Race/Tapered Roller

Bearing into the Trans‐

mission Housing”“ ,

page 217

4 - Inner Race / Tapered Roller

Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the

Inner Race/Tapered

Roller Bearing”“ ,

page 215

❑ Installing. Refer to

⇒ Fig. ““Heat the Inner

Race/Tapered Roller

Bearing and Press On

It”“ , page 216

5 - Differential

❑ With final drive gear

wheel

6 - Inner Race / Tapered Roller Bearing

❑ Removing. Refer to 

⇒ Fig. ““Removing the Inner Race/Tapered Roller Bearing”“ , page 216

❑ Installing. Refer to 

⇒ Fig. ““Heat the Inner Race/Tapered Roller Bearing and Press On It”“ , page 216

7 - Outer Race/Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing”“ , page 215

❑ Installing. Refer to

⇒ Fig. ““Pressing Outer Race/Tapered Roller Bearing with Shim into Clutch Housing”“ , page 215

8 - Washer

❑ Installation position: The collar on the inner diameter faces the right flange shaft seal.
❑ Allocation. Refer to the Parts Catalog.

9 - Clutch Housing
10 - Seal

❑ For the right flange shaft
❑ Allocation. Refer to the Parts Catalog.
❑ Replace when the transmission is installed. Refer to 

⇒ “1.3 Right Seal, Replacing”, page 209

 .

11 - Bolt

❑ 33 Nm
❑ Install with the threaded piece -Item 22- 

⇒ Item 22 (page 214)

12 - Right Flange Shaft
13 - Ring

❑ Pry the ring off the right flange shaft with a screwdriver
❑ Installed position: The depression faces away from threaded holes in flange shaft.
❑ Install the ring all the way by hand. Refer to 

⇒ “2.1 Overview - Differential”, page 212

 .

❑ The ring must lock into the flange shaft.

14 - Flange Shaft Pressure Spring

❑ Installed behind the flange shaft

15 - Thrust Washer

❑ Installed position: Collar to compression spring, braces (if installed) to tapered ring

16 - Tapered Ring

❑ Installed position: differential housing taper

17 - Locking Ring

❑ Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed

18 - Large Differential Bevel Gear

❑ Availability. Refer to the Parts Catalog.
❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 217

 .

19 - Differential Taper Axle

❑ Availability. Refer to the Parts Catalog.
❑ Remove using a drift
❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 217

 .

20 - Adapter Sleeve

❑ Availability. Refer to the Parts Catalog.
❑ To secure the differential bevel gear axle
❑ Removing. Refer to

⇒ Fig. ““Removing the Spring Pin for the Differential Bevel Gear Axle”“ , page 217

 .

❑ Installing. Refer to 

⇒ Fig. ““Installing the Spring Pin for the Differential Bevel Gear Axle”“ , page 218

 .

21 - Small Differential Bevel Gear

❑ Availability. Refer to the Parts Catalog.
❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 217

 .

22 - Threaded Piece

❑ Availability. Refer to the Parts Catalog.
❑ Installing. Refer to 

⇒ Fig. ““Installing the Differential Bevel Gears”“ , page 217

 .

23 - Thrust Washer Union

❑ Availability. Refer to the Parts Catalog.
❑ Install with transmission fluid

24 - Ring

❑ Pry the ring off the left flange shaft with a screwdriver
❑ Installed position: The depression faces away from threaded holes in flange shaft.
❑ Install the ring all the way by hand.
❑ The ring must lock into the flange shaft.

25 - Left Flange Shaft
26 - Seal

❑ For the left flange shaft
❑ Allocation. Refer to the Parts Catalog.
❑ Replace when the transmission is installed. Refer to 

⇒ “1.2 Left Seal, Replacing”, page 207

 .

2.2

Differential, Disassembling and Assem‐

bling

Special tools and workshop equipment required
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Press Piece - Multiple Use - 40-105-
♦ Press Piece - Multiple Use - 3005-
♦ Press Piece - Bushing - 3259-
♦ Press Piece - Reverse Gear Syncro - 3296-
♦ Bearing Installer - Wheel Bearing - 3345-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 6A - VAG1582/6A-
♦ Puller - Kukko Internal - 46-56mm - 21/07-
♦ Puller - Kukko Puller - 60-150mm Width, 200mm Length -

18/1-

♦ Puller - Kukko Quick Action Separating Tool - 12-75mm - 17/1-
♦ Puller - Kukko Counterstay - 22/2-
♦ Inductive Heater - VAS6414-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Seal - Right Flange Shaft
Removing the Outer Race/Tapered Roller Bearing from the

Clutch Housing
A - Counter Support , for example, -22/2-
B - Internal Puller 46 to 58 mm , for example, -21/7-

Note

♦

Tension the -21/7- -B- between the outer race/tapered roller

bearing and shim tightly -Item 8- 

⇒ Item 8 (page 213)

 .

♦

Check the shim for damage after removing it. Replace, if nec‐

essary.

♦

Instead of the -21/7- the -21/8- can also be used.

Pressing Outer Race/Tapered Roller Bearing with Shim into

Clutch Housing
– Install the old washer -Item 8- 

⇒ Item 8 (page 213)

 , into the

clutch housing.

• Installed position of shim: The collar on the inner circumfer‐

ence faces the seal.

Removing the Inner Race/Tapered Roller Bearing
– Before installing the puller, mount the -40-105- onto the dif‐

ferential housing.