39 Differential Manual Transmission Quick Data Index {Speed 091, 091/1 5-Speed 094) —Assembly 39.2 — Bearings 39.3-90.5 —Housing 39.3 =Pinion adjusting 99.10, 98.11 —Pinion/Side gears 38.6 —Ring goar 39.3, 39.4 adjusting 39.12, 98.19 backlash 39.13, 9.14 —Ring/Pinion gears adjusting 39.7-09.9 Shim 8 38.11 Differential—Auto. Trans, — See page 39.49 (094-4WD Syncro Differential with lock ‘assembly 39.20 bearing outer race 39.24 bearings 39.21-99.23 housing 99.21 pinion shafts 99.22 fing gear 39.20-29.23 = Diflerential without lock assembly 39.15 bearing outer race 39.19 bearings 39.16-39.18, housing 39.16 pinion shafts 39.17 fing gear 39,15-29.18 Driveshaft flange oil seal 39.44 removing/nstaling 39.43 —Front final drive 39.30, 39.31 adjusting rings 99.32, 39.33, axle flange 39.32, 39.33 Girclip 39.33 housing 39.34 ‘mounting 99.32 technical data 39.42 —Front pinion 39.39 ‘bearing 39.40 {grooved nut 39.40 turning torque 39.41 Locking pin 39.28, 39.28 ‘backlash 39.29 —Pinion/Side gears 39.25 —Remeving 29:33 Ring gearPision adjusting 39.26 backlash 20.27 screw-in depth 39.28, 39.27 ra) mx 39139 Differential-Manual Transmission cAUTION 2 Inna and outer races of tapered rote tarings oe mateked and must ot be auntie Hog interchanged, Replace both bearings at & pe ‘same time. Ring gear! pinion must be adjusted after replacing differential housing, cover or bearings. Side gear end play must be adjusted if differential rousing, cover or side gears have been repla Note Differentiat bearing/inner race a camnonnm —f oe coats, smicerada Ditlerontial cover see Repair Group 34 removing Fig. 3 when installing oi holes (arrow) must be Ditterentat bearing/ outer race removing Fig 10 instaling Fig. 11 Ring gearipinion adjusting, page $9:7-99,14 offset approximately 90° seas acusting, page 2919 fo atterentiat pion shat ‘Spacer determining size page 30.6 Thrust washers 7 check tor wear Side gears. Differential pinion gers intaling page 386 Differential pinion shatt drive out with drift. When Installing, do not thrust washers disassembling Fig Ring gear (matched to pin removing Fig.2 installing Fig 8 Ditferentiat bearing/outer 2c removing Fig, 10 installing Fig. 1 (rousing side) Femoving Fig. § and Fig. 8 Instaing Fig. 8 ~~ Ditterontial bearing/inner race r 0 © a 39.2 4-speed 091-091/1Differential-Manual Transmission 39 ousing oFig.1 2 pinion) ig 2 uter race: n hous il —— Md Ye Fiat Differential housing, sieassembiog — use jaw covers on vise Fig.2_ Ring gear, removing (matched to pinion) — use drift to separate ring gear from housing CAUTION ” Fig. 4 Differential bearinglinner race ("ing gear ‘side), removing Do not damage threuds in ring gear Ring gear ss [4-specd 091-091/1] S-speed oa4 | Bilnrternonine BOB39 bitterential-Manual Transmission Fig. 5 Differential bearing/inner race (housing side), removing — drill hole in VW 48711 as shown above (arrow) mm (116 in) 5 mm (818 in) 90-560) Fig. 6. Dilfrntlbeaingfiner race (hosing side), removing esis Fig. 7 Differential bearing/inner race (ring gear side), installing — heat to approx. 100°C (212°F) and press on Fig. 8 Differential bearinglinner race (housing side), installing — heat to approx. 100°C (212"F) and press on Fig. @ Ring gear, installing CAUTION Clean contact surfaces are essential to ensure that ring gear, differential housing, and cover fit properly. Remove all burrs and pressure marks with oll stone — heat ring gear to approx. 100°C (212% and instal entering pins (local manutact Note If ring gear/pinion are replaced, readjustment is necessary 39.4 Bitten [feapeed 081-091/1] “S-speed 094 |Differential-Manual Transmission 39 Fig. 10 Differential bearing/ outer race, removing Ba 562 using and : i” Fig. 11 Difforential bearing/outer race, installing = press race in until seated [Speed 094 | siiseniseungs ODD39 Differential-Manual Transmission Differential pinion/side gears, adjusting end play Note ‘Spacer sleeve ensures adequate backlash Detween side gears and differential pinion gears ‘even when there is axial pressure on side gears. If differential housing, cover, side gear ar spacer sleeve is replaced, size of spacer sieeve must be determined again — measure shortest spacer sleeve, Part No. (002 517 241, with micrometer and mark dimension on sleeve with electric marker or similar device, Sleeve should then always be used as measuring sleeve — place side gear with short shaft) and both thrust washers in cover — attach clamping sieeve VW 381/5a and clamp gear tightly against cover — place side gear (with long shaft) in differential housing — insert measuring sleeve, and bolt housing and cover together with 4 MB x 20 bolts — install dia! indicatoe with 3 mm range SA = Mi0x 25 bolt = WW 981/13 = 52 mm — zer0 dial indicator with 2 mm pretoad —find end play by moving side gear up and down add measured play and length of measuring sleeve together. Find this figure in taote w x range and select proper sleeve xrange ‘Sleeve lent Part Ro. 3187-9195 31.84 (002 817 24 31.98-32.04 31.93 002 517 . 32.05-32.13 32.02 02 517 2 32.14-9222 32.1 002 B17 2 32.23-32.33 32.20 — disassemble differential and remove measui sleeve — Install sleeve selected from above table and assemble differential without differentia pinion shatt — recheck play, Play should be +0.03-0.17 mm 4-speed 091-091/1 5-speed 094Differential-Manual Transmission H 4 uring e under 9 gear/pinion, adjusting Note Ring gear/pinion must always be replaced as mmatened set, never individually Ring gear/pinion markings ia 17 an Fa Serdce gears ie pros roduction gears 17 243, 1 = Marking K 738 means a a 7 2a Klingelnberg gear set with ratio of X =Markings x’edout are not shown on 17 248 728 teeth production gears i 2. =Matching numberof gear set 312 Po= Setting dimension for production ‘3 = Deviation r based on master gauge Col sand Used in special test machine In at Production, Deviation Fis always Gaim Given in 17100 mm. 28 shown in Example means that r=025 mm In production, position of pinion is Gotermined by dimension Po ing gear Ro= Length of master gauge in Centerline to back of pinion head) production: Re= 66 min Marking of deviation r on ring gear and R= Actual dimension between ring cear matching number have been discontinued. Centerine and end face of pinion at te i ais Faceeey co teaser quietest running point for this position of pinion before removing it when ceeteet parts which affect position of pinion are to Vo=Hypoid offset= 10 mm be replaced. See page 39.9 +6 speed 091-091/1 | 5-speed 094 ningcewionion Oak”39 Differential-Manual Transmission Ring gear/pinion, adjusting Note Ring geat/pinion must be adjusted it gears themselves have been replaced. It other parts CAUTION which affect position of pinion are to be Maximum possible care and cleanliness replaced, pinion depin R must be measured during all assembly and measuring before disassembling, and pinion set to this operations are essential for satistactory dimension when assembling, See page 99. results Fig. 9 Ring gear/pinion adjustment points + S:=Screw-in depth of adjusting ring (ting gear side) Screwin depth of adjusting ring {housing side) + $1= Shim for pinion +s: Ring gear/pinion adjustment procedure Work sequence rew-in depth &: and Ss 3d roller bearing preload is determined by ring gear turning torque — adjust pinion and check S: ‘adjust pinion with shims so that correct dimension R is attained — adjust backlash 39.8 sinc cominion 4-8peed 091-091/1| 5-speed 094 “ Wi setDifferential-Manual Transmission 39 Ring gear/pinion, adjusting ate Lis only necessary to adjust pinion, ring gear, o both, or shift forks If parts which directly influence setting have been replaced. See table to avold unnecessasry adjustments ‘To be adjusted - ion Ss Pinion Ss Shift forks | from actual trom Ring gear see | dimension R | deviations | Srand Ss Repair 30 see se Pants replaced Group 35 | page 88.9 | page 39.10 | page 39.12 Transmission case x % x ‘Adjusting ring for fival drive x Differential housing ~ x ~ cover for diferent housing x ~ Diferental tapered roller bearings x Double tapered roller bearing for pinion | __X x ing gear/pinion x x x Balrbearing for ave shat x j Finding position of pinion — measure difference from Ro. This measurement fail eo ee Corresponds to deviation f. Note reading Example: = 0.25 mm esi postion ot pinion Js only necaeean —after installing new parts, adjust pinion. See son seviaion vig hot arid one eae, and ages 39.10-39.11. Deviation ris Used to narts are to be replaced which directly influence determine thickness of shim Ss postion of pinion. These are: both pinion bearings and transmission housing. Work sequence ~ remove differential housing ~ assemble measuring bar as described on page 198.10 and place it In transmission housing ww 385/11°0 set gauge VW 385/30 to Ro = 63.00 mm, place fn bar and zero dial indicator (3 mm range) with 1 mm preload _———— 4 [a-speed 091-091/1] _5-speed 094 spon sdusing BDL39 _Differential-Manual Transmission Pinion, adjusting Neo Ring gear/pinion need adjusting if gears themselves have been replaced. If other parts. which affect position of pinion are to be replaced, setting must be measured before disassembling and pinion set to this dimension when assembling. See page 39.9 Work sequence — Install tapered roller beating and needie bearing inner race for 1st gear an pinion shaft — torque needle bearing Inner race to 210 Nm (162 ft 1b) vw3eVl4 — install pre-assembled pinion in transmission housing without shim Ss — install retaining ring and tighten with VW 381/14 to 225 Nm (162 ft 1b) — back off and retighten to 225 Nm (162 ft 1b) Finding dimension — screw in one adjusting ring until flush with transmission housing pare) — adjust setting ring on measuring bar VW 38611 to dimension a # a = approx. 57mm 3855 W354 vw38s vwses4 Ee — assemble measuring bar as shown * dial gauge extension VW 385/16 = 123, — place measuring dise VW 385/17 on end of Pinion’ — place measuring bar in housing and screw 2nd adjusting ring in until flush with housing — move 2nd centering ring VW 385/4 outward with movable setting ring on measuring bar Until bar can just be turned by hand — se universal gauge VW 985/30 to Ro= 63.00 mm and place it on measuring bar — 2e10 dial gauge (3 mm range) with 1 mm preload Note Gauge VW 385/11 can be used instead of universal gauge VW 385/30 4-speed 091-091/1 5-speed 094 39.10 rier striveDifferential-Manual Transmission 39 rn 30-608, 212.3 mm ~turn bar until measuring pin touches measuring disc on end of pinion, and needle shows maximum deflection, This is dimension e Examph Shim $s, determining thickness = measured figure (max. deflection) {C= deviation (marked on ring gear in 1/100 mm or found by actual measurement) ample Dial gauge reading fore 0.40 mm Deviation r 40.25 mmo Sishim thickness 65mm Si shims available Part No. (007 311 397 01 311 392 001 311.393, 001.311 394 001 311 395, 001 311 396 Note Shim tolerances make it possible to select any required thickness for Ss Measure shims at several points with micrometer and check for burrs and damage Use only shims which are in good condition {imension 1, checking — install pinion with measured shims Ss and turn several times in both directions — place measuring bar in position and check ‘measurements, ‘if shims have been selected correctly, dial ‘gauge (reading counterclockwise), should show deviation r within tolerance of 0.04 mm ‘Adjustment eae ‘VW385/16 VW385/14 rir vw385/1 vw3e5/4 4-speed 091-091/1 S-speed 094 can 39.14139 Differential-Manual Transmission Ring gear, adjusting (pinion removed) Ring gear must be adjusted if transmission housing, differential bearings, differential housing/cover, adjusting rings or ring gear! pinion have been replaced. Also see table on page 33.9 Work sequence CAUTION Differential bearing outer races must be fully seated In adjusting rings — install differential with ring gear on driver's side — install dial indicator (3 mm range) with extension VW 382/9 into bar VW 38217 = zer0 dial indicator with 1 mm preload vw 382/7—. vw382/9 VW 381/15, — turn in adjusting ring on ring gear side with ‘VW 381/15 until upper edge is approximately 0.20 mm below surface of housing — tum in adjusting ring on other side with YW 381/15 until differentia’ is free of play and without preload — attach VW 281/8a to ring gear side and lock with hex nut — turn trangmission housing so differential i top and attach bridge VW 381/8 on dowel pa 4-speed 091-091/1 B9A2 noon adjustingDifferential-Manual Transmission 39 inh ately y lock is at el pins yw 381/8 Eh VW 381/ 5a: Lia VW381/8 ~ attach torque gauge US 1064 —turn differential in both directions while oiling bearings with transmission oil ~ increase bearing preload slowly by turning in adjusting ring on side opposite ring gear with YW 381/15 while turning differential with US 1064 until specified turning torque is reached ‘Turning torque New bearings: Used bearing 500-350 Nem 30-70 Nem (27-31 in. tb.) (2.7-6.2 in, Ib) “alter running at least 30 miles = measure screw.in depth of adjusting rings and rote readings $: and Ss — mark adjusting rings and do not interchange Note Ning gear is being readjusted, check pinion agjusiment, See page 39.10 Backlash, adjusting Work sequence — install pinion wiah shim So — install fterential with adjusting tings on correct sides — attach bridge VW 38178 turn in.adjysting rings while turning differential until measured screw-in depths ‘Si and $1 have been reached. — attach measuring tools as shown 4-speed 091 — lock pinion with bar VW 381/11 4-speed 091-091/1| 5-speed 094 senemcste 39.1339. Differential-Manual Transmission CAUTION I backlash readings vary by more than 0.06 mm from one another, there is something wrong with installation of ring gear or gear Set itself. Check all assembling operations. and replace gear set if necessary — to adjust backlash, proceed as follows — turn adjusting ring on side opposite ring gear out — tum adjusting ring on ring gear side in by ‘same amount — continue adjusting until backlash is 0.45-0.25 mm (0.006-0.010 in.) lock pinion with clamp ioe +A bolt MB x 126, Keep within tolerance of 0.01 mm ‘S—speed 094 Backlash, checking — check backlash each 1/4 turn * backlash should be (0.15-0.25 mm (0.006-0.010 in) Note Individual readings must not differ by more than (0.05 mm —T_ Gena] lock pinion with clamp + Am bolt MB x 125 — turn ring gear to stop and set dial indicator tozero — turn ring gear in opposite direction and read backlash — check backlash each 1/4 tum * backlash should be (0.15-0.25 mm (0.008-0.010 in) Note Individual readings must not differ from one another by more than 0.05 mm. 39 : 1 4 —— 4-speed 091-091/1 5-speed 09439 Differential — Manual Transmission Note Clamp ditferential gear into a vise before disassembling (Fig. 1). ‘Adjusting ring Diferentialbearingiouter race Fig. 19 Instaling Fig. 14 Differential bearinginner race (ing gear slde) removing Fig. 4 Instaling Fig. 10 50 Ne (96 ft) {ghten diagonally Dierentiat cover removing Fig. ‘Thrust washer chock fo woar ron rg ol his most be ton spray 9" Sere pion shah _*R Dita side gore. toro tan tei, Son wan nor Won pag, dst one ay ‘Spacer termining siz, page 69.25 a a Phos Nop 8 Ditton shat GES papeeles ‘on naling. co not CY See ; ena Differential bearingiouter race removing Fig. 13 insaling Fig. 14 Tanomission housing Ditferential ‘small differential pinions ‘CAUTION Bearing inner and outer races are matched ‘and must not be interchanged. Replace both bearings at the same time. Ring gear and pinion must be adjusted after replacing diferential housing, cover and bearings. Side gear end play must be adjusted if diferential housing, cover or side gears have been teplaced, ‘Thrust washer check for wear Thrust washers check for woar =, "Sie, otaation pation Fe Dierential aide goar long shaft in housing. shot shat in cover When replacing, aust end play ao Dittrontal rousing ‘Thrust washers check for wear 26 exec Ditorertal pinion shat (shor SNF removing Fa. 7 tive in fush Differential pinion shaft removing Fig. 6 ‘when instaling, do not damage trust washer romoving Fig. 2 Ditferential gear set with four ‘small differentia! pinions inating Fig. 12 Diftrental besringinner race ‘housing side) removing Fig. 5 instaling Fig. 14 Dittrental housing Ring gear (ratched to pinion) 094-4WD 39.15 semhere ar Pinions estton Fig. 8] st ond play Differential — Manual Transmission 39 Fig. 1. Ditferential housing, disassembling — use jaw covers on vise Fig. 2. Ring goer, removing — use drift to separate ring gear from housing ‘CAUTION Do not damage threads in ring gear: Fig. 4 Differential bearing/inner race (ring gear ‘skie), removing DeaWD ) Diterentat using 39.16 Diferontl Deering OOD)39 Differential — Manual Transmission — VW412 40-21 vw457/1, 'W457/2! h \wwased Fig. 7 Ditferential pinion shafts (short), removing Fig. § Differential beering/inner race (housing side), removing — insert greased ball A (17 mm diameter) Into bore hole of spacer up to stop and Fig. 6 Differential pinion shatt (long), removing — drive out axle unti it projects 70 mm on ‘one side Fig. 8 Differential pinion shatts, Installing —align short shafts with slots parallel to lange — drive in all shafts unt thrust washers and ditferential pinions can be positioned — instal spacer with large bore hole a facing long axle — drive in long axe untl it matches pin hole 39.17 soxre= [oweDifferential - Manual Transmission 39 Fig. 11 Ditterentia! bearing/inner race (housing ‘sde), installing — heat to approximately 100°C (212°) and press on Ih ey Wooo Fig. 10 Difterentla! bearing/Inner race (ring gear q se}, intaling ai A — heat to approximately 100°C (212°F) and Press on ‘CAUTION Clean contact surfaces are essential to ensure that ring gear, citferential housing and cover ft properly. Remove all burrs and pressure marks with ol stone. a | a — heat tn goer spray 100 een eal A = centering pins (fabricate) ia ‘Note = tra gems lcd, chao - necatey 7 os4-4wD | Morente vearrae 3.1839 _ Differential — Manual Transmission Fig. 14 Ditterential bearing/outer race, installing — press race in until seated 39.19 cents ermpot nee Loo4¥oDifferential —- Manual Transmission 39 vere CAUTION deanenting eo Bauing inner and outer 260 ae matched tnd mst not be rehanged. Peplace both Aaatng toa Dearne ath sro tne: Rng gear an pinion must be adjusted after replacing + — mount support to flange and remove hex nut }++204,5mm —dfil an addtional 9.0 mm (0.35 in.) dameter hole in bracket VW 457/2 39.35 Fate imDifferential - Manual Transmis: — remove flange, use two-armed extractor it necessary — remove flange shaft — remove both ball bearings A— Puller, eg. 22-2 B — Inner extractor, 30-37 mm, e.g. Kukko 21/5 ‘Assombling Betore assembing: — poston shim 83 = place 12 point of dul beering on opening in housing — heat pinion housing at dual bearing seat to — remove needle bearing from flange shaft 40-60°C (190-166) ~ — ctv pinion in using a plastic hammer imeem — position washer and install retaining ing B— mer extractor 12 — 14.5 mm, 0.9. Kukko ant — pry seal out trom cover — remove seals for outer and inner ball bearing —tighton retaining ring to 226 Nm (166 ft Ib) — loosen retaining ring and retighten to 225 Nm (166 ft tb) a 004-400 | pon micve SISO39 _ Differential — Manual Transmission — drive seal in to stop — secure retaining ring by staking in two places ‘A— fabricated staking tool —Inetall speedometer drive — push both ball bearings up to stop in back cover — install crcips 39.37 verte vwan ‘VW434 [cones] — press in flange shaft needle bearings — Install flange shaft ito output housingDifferential - Manual Transmission 39 — push on driveshaft flange — insert washer — mount puller and tighten hex nut to 160 Nm (118 ft ib) — position viscous coupling on pinion — coat spacer ring with grease and align on viscous ‘coupling — position output housing and tighten 094-4WD rowtnadie 39.3839 Differential — Manual Transmission Retaining ring Lighteningoosering, pages 99.96 and 29.87 Dual taper roller bearing removing Fig. 2 Inataing Fig. 3 determine poston of pinion ror to removing, page 39.25 check turning torque Figs. 4 and § ; Shim $3 Pinion inion and ring gear are matched set ion and ‘Speedometer deve gear adjusting, pages 39.26 and 39.29 Lehnert ‘ro0ve facing outwards ‘Grooved nut 210 Nm (155 f 1b) removing Fig. 1 39.39 resin LoreeDifferential - Manua!-Transmission 39 Fig.1. Grooved nut, removing/installing (at final drive with viscous coupling) — instal and tighten grooved nut to 210 Nm (155 ft Ib) — check turning torque of bearing vw4o09——_ (itt Fig. 2 Bearing, removing Fig. 3. Bearing, installing — heat inner rings to approximately 100°C 12) — position and press in 094-4WD owaxig 39.4039 Differential — Manual Transmission Fig. 4 Bearing turning torque, checking ‘A— Commercial gauge, 0-600 Nem (054 in. i) — lubricate bearing with hypoid transmission il —tighton retaining ring as specified ‘—olate pinion in both directions 16-20 times without interruption — rotate again and read turning torque ‘Turing torques ‘Now bearings Used bearings” to 210 Nem to 70 Nom (19 in. bo) (62 in. by ‘after running at least 30 miles Fig. § End play, checking =f uming torque equals zero, check pinion shaft bearing for end play —it any ond play is felt, replace beating 39.41 sapere Looe awoDifferential-Manual Transmission 39 Technical data + code letters * application * gear ratios Front final drive code letters ACU date of manufacture from 10/85 to ‘Application vehicle ‘Vanagon Syncro engine 2.1 Liter 70 kw (95 bhp SAE net) marival transmission AK ‘AN Ratio 34:7 = 486 Capacity 1.6 US Qt (1.5 Liters) “Lubricant specification Goar oll GL-4 SAE 80 ‘Axle shaft flange 100 rm [Sinero] reymmiare 39.4239 Differential — Manual Transmission Driveshaft, removing/installing '— remove bolts (arrow) at front and rear driveshalt flanges and remove driveshaft Installing — instal rveshatt and tighten bots to 95 Nm — leoeen mounting bolt of front final dive (rrow) sn) Do NOT remove bot, — loosen side bolts of front final drive mounting Note bracket (arrow) Do NOT remove bot (On vehicies with fuel injection and rubber damper (on driveshaft (arrow), damper faces transmission CAUTION Front final drive mounts MUST be loosened aligs front final drive in longitudinal direction and to prevent damage to the driveshatt universal tighten mounting bolts joints when removing driveshafts. ‘CAUTION Front final drive alignment must be done to ensure driveshaft is installed without distorton. transmission housing or engine block. Note ‘The universal joints cannot be replaced using standard workshop tools and are not available as replacement parts 39.43 sins, emovoinaating [S16Differential-Manual Transmission 39 Driveshaft flange oil seal, replacing ton wor mat ee terenintcn Work sequence tere vn (one page 30.) 660) = Ny, - We ons aren forge See rote a ie he) — TAS Sind ara von nso 26m (26 ft Ib) ianove teal Boge Vee sam cae foe ae oa Ecaiae ou eae ed ro a vee tang ot oes OD4AG39 Differential — Manual Transmission Front final drive axle flange oil seals, replacing WF both lot and right oil seals are 10 be replaced, remove front final drive (see page 39.47). 3d. on one side onl Hf the oil seat is to be replacec remove suspension as described below. Work sequence — remove bolts connecting axle shaft to flange Femove spacer ring removing bolts (arrows) — remove bolts (arrows) and separate radius rod, wheel bearing housing and lower control arm 39.45 cm: [oneDifferential-Manual Transmission 39 — remove whee! beating housing complete with — install whee! bearing housing with axle shaft axle shaft — install bolts for radius rod, wheel beating — perce oap in drive flange with screwdriver and hhousing and lower control arm ry out — remove circlip and wave washer [caurion———“—NSSS~<‘C~*Y — install tie rod, brake caliper and upper ball joint — install brake hose bracket — bolt axle shatt flange with spacer washer to drive flange = remove drive flange with VW 391 Temove tok ring Do not damage axle shaft boot Tightening torques radius rod/whee! bearing housing on control arm 100 Nm (73 f Ib) brake caliper to housing 240 Nm (177 ft Ib) wheel bolts "180 Nm (132 ft Ib) axle shatt to drive flange ‘35 Nm (26 ft Ib) ball joint to upper control arm 60 Nm (44 fb) Hl — drive in new cil seal to stop — install lock ring — install drive flange with VW 391 — install wave washer — Press circlip into groove with VW 454 and at ‘same time check that washer is centered — replace cap 7 Synero] nan eas 39.46,39 Differential — Manual Transmission Front final drive, removing/installing 3 final drive mounting ide bolts of front bracket (arrow). Do NOT remove bolts. — loosen si Syncro S947 erst se novaDifferential-Manual Transmission 39 NI \ FAM LE \\AY © =1663] — support final drive with transmission jack and small adapter (@ mechanics raquired) Installing rder of removal and note the following: = tighten mounting bolts of front and rear brackets last Tightening torques. ‘axl shaft to final drive 95 Nm (26 ft it) rveshaft to final drive 35 Nm (26 ft Ib) Syncro wcingmesin; 394839 Differential Automatic Transmission Index Adjusting ring 39.51 —Assembly 39.56 —Cover plate 39.51, —Ditierertial bearing outer race 39.53 Drive flange oil seal 39.53 Final drive assembly 39.50 Governor oll seal 39.52 Pinion bearing outer race 39.52, 39.54 inner race 39.54, 39:55 Pinion oil seals 39.52-30.54 —Ring gear 39.56 =Ring gear/Pinion adjusting 39.57- 39,60 backlash 99.61, 39.62 ~Torque converter oll seal 39.51 39.4939 Differential-Automatic Transmission Final dri Fina ive rats ‘CAUTION Final érive lubricant: It ing gear/pinion bearings can be reused it Hypoid oll SAE 90, MiF-L2105 B is necessary to measure backlash (page Capacity: 39:18) and turning torque on pinion (page 125 (1.3 US Qt) 39.14) before disassembling final drive. Note these measurements and adjust during reassembly to obtain same settings Pinion oll seals Pinion bearing outer race removing Fig. 13, removing Fig. 18 installing Fig. 14 Installing Fig. 17 ‘and Fig. 18 Oil seal sleeve removing Fig. 18 Governor Instaling Fig, 18 isassembling! assembling alimbtecogikas vaca S528 Repair Group 38 removing Fig. 18 Installing Fig. 19 tenia Cover plato instaling Fig. & it hole seal - instaling Fig. & = ‘Shim 8) etormining thickness Pinfon bearing lnner race Page 9959 Femoving Fig. 18 Installing Fig. 20 Ditforentiat bearing outer race remove with aritt installing Fig. 12 Installing Fi 3 Pinion bearing outer race removing Fig? inataling Fg 8 Pinion ol sea moving Fig & instating Fig 8 Dierentist ‘isascombing age 39:56 10 Nem 7 ft tion daze Driv ange ol sea Aatuating rng tier nts canbe repaced wi» ark poaion bore reg. Sminsios fiat ve iatalog ‘Wen elacing bearings bee Ropar Group 37 read ring gear pag 3860 wtaling Fig temovnginwating Po 8 39.50 snaaieDifferential-Automatic Transmission 39 smbiing 8 (eam Fig. 1 Final drive housing, mounting deve housing nig in repair Fg pearion be readusted ice, page $057 Cover plate/Oi! hole seal, installing — first insert seal (arrow) for oil hole — install cover plate and tighten to 25 Nm (18 ft Ib). Use sleeve 2058 when installing cover que converter vs rng Fig. 2 jaling Fig. 3 jon bearing er race paving Fig, 7 tang Fig. 8 ion oil seal wowing Fig. 8 tating Fig. 9 terotiat assemsing 03956 Fig.2 Torque converter oll seal, removing Nn 1) rar intervals of Fig. 5 Adjusting ring, removing/installing — when reusing ring, mark position betore removing E2 Torque converter oll seal . sumtin 39.5139 Differential-Automatic Transmission Fig. 8 Pinion bearing outer race, installing drive in untit seated Fig. 9 Pinion oll seal, installing ee, ES + seal lip faces converter Fig.7_ Pinlon bearing outer race, removing Fig. 10 Governor oil seal, omovinglinstalling = remove seal with VW 24811 together with adapter 248/2 — drive in oil seal until seated using ‘VW 248/1 without adapter (seal lip faces governor) Pinion oll seal 39.52 SaDifferential-Automatic Transmission 39 Fig. 11 rive flange of seal, Installing = ll space between lips with mult purpose grease and press in flush Fig. 12 Differential bearing outer race, installing — press in until seated US 1037, or KUKKO 21/7 Fig. 13 Pinion oll seals in cover plate, removing — press out seals individually VW 295 vwstt Fig. 14 Pinion oil seal (inner) in cover, installing ~ drive seal into cover until seated Open side of seal faces final drive Drive flange oll seal Differential bearing outer race Pinion oil seals 39.5339 Difterential-Automatic Transmission |—vw sst Ea Fig. 15 Pinion oll seal (outer) in cover, installing = drive seal into cover until flush. ‘Open side of seal faces transmission i a or. ie KUKKO 21/7 ca | Fig. 16 Pinion besting cuter race In cover, removing Fig. 18 Pinion bearing inner race/Oil sexe removing — press off bearing together with sea! Sleeve (tool US 1103 can be usec) Pinion oll seal 39 is 54 Pinion bearing outer race Pinion bearing inner raceDifferential-Automatic Transmission 39 Fig. 19 Pinton bearing inner raco/Oil seal sleeve, Installing — heat bearing and steve to approx. 100°C (212"F) — press onto pinion shaft h seal Fig. 20 Pinion bearing inner race, installing — heal inner race to approx. 100°C (212°F) ‘and press into shaft By 56 Pinion bearing inner race 39.5539 Differential- Automatic Transmission 70 Nem (5111) Difterentlat housing cover Differential pinion shatt remove and install with gett fing gear, page 28.60, Drive flange nut align igs wnen ‘stating Fig. 3. Ring gear, installing = heat ring gear to approx. 100°C 12°F) ‘A=centering pins (local manutactue Fig. 1 Differential bearing/ Inner race, removing Fig. 2 Ring gear, removing = mount differential in vise Fig. 4 Differential bosring/Inner race, installing — loosen bolts anc tap lightly on bolt — heat bearing to approx. 100°C (212°F) heads and press on 39.56 itsoDifferential-Automatic Transmission 39 Ring gear/ Pinion, adjusting Note Ring gear/Pinion may only be replaced as matched set > ae SFr) "6 (212°F) anufacture) Position of shims $:/S- Ao= Length of master gauge used in factory testing machine. Ro= 52.60 mm 1 =Deviation measured against master gauge of testing machine used in production Deviation ris always given in 01 mm. For ‘example 52 means ¢=0.62 mm $1 2 Shim for bearing preload (behind pinion head) $4 = Shim for pinion position (opposite end) Note 1 pinion bearings will not be changed, measure turing torque of pinion before disassembly and adjust to same turning torque during assembly Marks on ring gear 1 Identitication G 1145 refers to Gieason gear Installing set with ratio of 11:45 "oer 2=Serial number of matched gear set 3= Deviation ¢ ning gern, sdusing ODD L es ]eo39 Differential-Automatic Transmission Pinion, adjusting Work sequence — Install bearing outer race into cover plate and housing — heat pinion bearing inner races to approx. 100°C (22°F) — press inner bearing races, without shim, on pinion shaft with approx. 3 tons pressure — insert pinion in housing, Install cover plate land tighten to 25 Nv (18 ft Ib) VW 385/17 ——~wl — install dial gauge holder VW 387 on housing = place measuring plate VW 385117 on pinion shalt — install dial gauge and set to zero with 1 mm. proload — move pinion up and down without turning ang note measurement CAUTION. Measurement will be inaccurate if pinion turns: — add 0.10 mm for bearing preload and 0.10 mm for bearing settling to reading. Result is S total Example measured reading 2.48.0 bearing preload 40.1000) settling allowance constant) $0.10 Total shim thickness (Stotal) 2.66 = remove pinion shaft — Install shims corresponding to total shim thickness § total on end opposite pinion head = reinstall pinion turn pinion several tim In both directions — attach measuring plate VW 385/22 with ‘support WW 885/19 to pinion — set clamping ring on universal measuring b © 8 = approx. 74 mm (2.913 in) — assemble measuring bar with dial indicator extension VW 85/20 — turn adjusting ring on left side into hausing until flush 39.58 sion ajsiveDifferential-Automatic Transmission 39 — insert measuring bar into housing and screw Shim &., determining thickness in adjusting fing nin Se Cetermining t sat [s=s0u-s | +010mm ee +010mm Example =268mm total shim thickness 2.66 mm Ss thickness 4.30.mm shim Se thickness =1.36mm inion head pene — select shims from table below rections, Shims available Shim thickness Shim to be ~ inge inmm installed —_—Part N ia 1.050-1.100 1,100 082 519 141 AE : 41105-11125 125082 519 141 AF 4430-1:150 1150082 519 141 AG move centering dise outward with movable setting ring until measuring bar can just be eee ee ee at « turned by hand 1.180-1.200 1200 082 519 141 AY 11208-11228 1228 082510 141 AK 7 1.230-1.250 1.250 062 519 141 AL 1258-1275 1275082519 141 AM 1280-1:300 11300082 619 141 AN . 1906-1925 1.925 082.619 141 AP 1330-1350 360082 519 141 AQ war 1355-175 1375 082.619 141 AR with - 1.380-1.400 1.400 082519 141 AS. = 1.405-1,425, 1.425 082 519 141 AT 1.430-1.450 1450 082.619 141 BA 1485-1475 1475 08261814188 1480-1500 11600082519 141 BC =e 7 11505-1525 11525 082519 141 80 ~ place master gauge VW 385/21 on measuring 5: bar and zero dial indicator with 3mm preload 10 on oeee ray BE al ~ turn measuring bar until dial indicator pin 11S les eeoie a1 BF asuring bar contacts end plate and gauge shows 1.880-1.600 1,600 082 619 141 BG maximum deflection (retuen point) 1.605-1.625 1.625 082619141 BH — note reading @ (example: 1.72 mm) and 1,650 082 519 141 BU Getermine thickness of shims Ss and Sx 11675082 519 141 BK » hte 1.700 082619 141 BL 1.705-1.725 1.725 082519 141 8M Master gauge VW 485/90 can be Used instead of |——_1.70-1.750, 11760082519 141 BN 1.8 i ‘Wester tS Fe aac na, 1.785-1.775, 1.775, 082 519 141 BP determi 1780-1.800 11800082619 141 80 indicator bamaba eas: 11805-1825 1.825 082519 141 BR 7 1.890-1.850 1850 082 519 141 BS ‘housing 1855-1875 875 082.519 141 BT 11880-1,900 1.900082 619 141 CA Example N ial indicator reading e 4.72mm ote deviation r marked on ring gear =042mm Measure shims at several points with lenonnese Sasomm Micrometer, Check for burrs and damage. Use ’ ‘only good shims ~ select shims from table — go to next page E40 ” ren steno BOLOD39 Difterential-Automatic Transmission Ring gear, adjusting Ba Work sequence Wo — install diferential and pinion ~ coat O-rings and threads of adjusting rings ‘ lightly with multkpurpose grease — lubricate bearings lightly with hypoid gear olt — screw in both adjusting rings vatit outer Surtees usr housing surace — install shims selected from table 8: behind pinion + 8 opposite pinion — Install pinion = lubricate bearings with hypoid gear cit : — tum pinion several times in both directions = Install universal measuring bar = 2er0 dial indicator with 1 mm preload — check that indicator reading equals recorded deviation within a tolerance of 0.04 mm carefully urn adjusting ring behind ring gear Lntit ring gear meshes with pinion with no backlash ‘ow in adjusting ring Opposite ring gear as far a8 possible and preload slightly so that Us 1064 3 ‘or US 1065 9022 V — after installing selected shime and pinion shaft, check that turning torque is at least 140 Nom (12.4 in. Ib) Note This figure is for new bearings. f bearings are to , be reused, turning torque should be measured 1 before disassembly. When replacing parts that e affect ring gear/ pinion setting, check page 30.9 t to determine which parts need to be adjusted th — tum adjusting ring behind ring gear 2 1/2 tooth divisions out (right arto) / — tum agjusting ring opposite ring gear 6 tooth divisions in (let arrow). This corectly sete bearing preload and gear backlash 3 39.60 sects.jog gear jth 90. j gear a8 so that Differential-Automatic Transmission 39 Backlash, checking Work sequence turn pinion several times in both directions ~altach measuring tools as shown oo. -VW388 ~set measuring lever to 80 mm and place on yw satis install dial indicator (3 mm range) with extension VW 382/10 (6 mm flat end) in holder VW 987 and bolt holder to transmission housing Note Dat indicator must be located at right angle to ireasuring bar — turn ring gear untlt measuring lever contacts pin of dial indicator a and preloads It to 41.0 mm. Reset dial indicator to zero — attach clamp VW $88 to cover plate and lock pinion with clamping screw — go to néxt page E13 sxc erecting BDO 139) ifterential-Automatic Transmission — check backlash at four positions * backlash should be: 0.15-0.25 mm ‘CAUTION Individual readings must not differ by more than 0.05 mm. Backlash figure given above ‘only plies (0 new ring gear/pinion. M used set of geara fs relnstalled, they should be set to give same backlash with which they were running before they were removed Note If backlash of new ring gear! pinion is outside tolerance, it must be corrected by turning both. adjusting rings by same amount (in opposite directions) so that bearing preload is not changes — measure total turning torque of all bearings with torque wrench on pinion shatt — total turning torque must be at least 20 Nem (1.8 In, Ib) more than turning torque of pinion shaft alone. I necessary, increase turning torque by screwing in both adjusting rings by same amount 39.62 srccuen cing ew