Volkswagen Tiguan Service and Repair Manual: Differential

Overview - Differential

Overview - Differential, Front Wheel Drive

Note

• To install, heat the bearing inner races/tapered roller bearing to approximately 100 ºC (212 ºF) with Inductive Heater -VAS6414-. Wear protective gloves.
• Replace both tapered roller bearings together.
• Adjust the differential when replacing the tapered roller bearing, differential housing, transmission housing or clutch housing.

1. Transmission Housing
2. Shim
   • For the differential
   • Selecting thickness.
3. Outer Race/Tapered Roller Bearing
   • Removing.
   • Installing
4. Bearing Inner Race/Taper Roller Bearing
   • Removing.
   • Installing
5. Differential Housing
   • With differential bevel gears, thrust washer union, differential bevel gear axle and final drive gear
   • Differential Bevel Gear, Thrust Washer Union and Differential Bevel Gear Axle, Removing.
   • Differential Bevel Gear, Thrust Washer Union and Differential Bevel Gear Axle, Installing.
6. Bearing Inner Race/Taper Roller Bearing
   • Removing
   • Installing
7. Outer Race/Tapered Roller Bearing
   • Removing
   • Installing
8. Washer
   • Installed position: the collar on the inner circumference faces the right flange shaft
   • Allocation. Refer to the Parts Catalog.
9. Clutch Housing
10. Seal
    • Replace after removing
    • For the right flange shaft
    • Allocation. Refer to the Parts Catalog.
    • Replace when the transmission is installed.
11. Bolt
    • 33 Nm
    • Replace after removing
12. Right Flange Shaft
13. Protective Ring
    • Pry the ring off the right flange shaft with a screwdriver
    • Installed position: the depression points away from threaded holes in flanged shaft
    • Install the ring all the way by hand
    • The ring must lock into the flange shaft.
14. Flange Shaft Pressure Spring
    • Installed behind the flange shaft
15. Thrust Washer
    • Installed position: the collar faces toward spring, and tab, if equipped, faces toward tapered ring
16. Tapered Ring
    • Installed position: ball toward the differential housing
17. Circlip
    • Holds the tapered ring, the thrust washer and the pressure spring when the flange shaft is removed
18. Protective Ring
    • Pry the ring off the left flange shaft with a screwdriver
    • Installed position: the depression points away from threaded holes in flanged shaft
    • Install the ring all the way by hand.
    • The ring must lock into the flange shaft.
19. Left Flange Shaft
20. Seal
    • Replace after removing
    • For the left flange shaft
    • Allocation. Refer to the Parts Catalog.
    • Replacing

Differential, Disassembling and Assembling

Differential, Disassembling and Assembling, Front Wheel Drive

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-
• -1-Puller - Kukko Internal - 46-56mm -21/7-
• -2-Puller - Kukko Puller - 60-150mm Width, 200mm Length -18/1-
• -3-Puller - Kukko Quick Action Separating Tool - 12-75mm -17/1-
• -4-Puller - Kukko Counterstay -22/2-
• Inductive Heater -VAS6414-

Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing

1. Counter Support, for example, Puller - Kukko Counterstay -22/2-
2. Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm -21/7-

Note

• Tension the internal puller-B- between the outer race/tapered roller bearing and shim tightly -item 8-.
• Check the shim for damage after removing it. Replace, if necessary.
• Instead of the Puller - Kukko Internal - 46-56mm -21/7- the Puller - Kukko Internal - 56-70mm -21/8- can also be used.

Pressing Outer Race/Tapered Roller Bearing with Shim into Clutch Housing.

• Install the old washer -item 8- into the clutch housing.
• Installation position of washer, shoulder on inner diameter points toward seal in clutch housing.

Removing the Bearing Inner Race/Taper Roller Bearing

• Before installing the puller, mount the Press Piece - Multiple Use -40-105- onto the differential housing.

Heat the Bearing Inner Race/Tapered Roller Bearing and Press on It

The cage with the tapered rollers must rotate easily when being installed.

WARNING

Removing the Bearing Inner Race/Taper Roller Bearing

1. Puller - 60-150mm Width, 200mm Length -18/1-, for example.
2. Puller - Kukko Quick Action Separating Tool - 12-75mm -17/1-, for example.

Heat the Bearing Inner Race/Tapered Roller Bearing and Press on It

The cage with the tapered rollers must rotate easily when being installed.

WARNING

Wear safety gloves.

Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing

1. Counter Support, for example, Puller - Kukko Counterstay -22/2-
2. Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm -21/7-

Note

Instead of the Puller - Kukko Internal - 46-56mm -21/7- the Puller - Kukko Internal - 56-70mm -21/8- can also be used.

Installing Outer Race/Tapered Roller Bearing into the Transmission Housing

• Support the transmission housing directly under the bearing mount using the Bearing Installer - Wheel Bearing -3345-.

Removing the Spring Pin for the Differential Bevel Gear Axle

• Use a 5 mm diameter drift -B- to remove the adapter sleeve -A- from the hole -arrow- on the differential housing.

Note

• If there is no hole -arrow- on the differential housing, remove the adapter sleeve as follows:
• Cover the inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.
• Remove the adapter sleeve using a chisel.

Installing the Differential Bevel Gears

• Insert thrust washer union with transmission fluid.
• Install and secure both large differential planetary gears, for example, with a flange shaft.
• Insert the small differential planetary gears 180º offset and pivot them into position.
• Press the differential bevel gear axle -arrow A- up to the first small differential bevel gear.
• Insert threaded pieces -arrow B- into the large differential planetary gears.

• Installed position: shoulder faces the differential bevel gear
• Install the differential bevel gear axle up the end position and secure it with a new spring pin

Installing the Spring Pin for the Differential Bevel Gear Axle

• Align the hole in the differential bevel gear axle to the hole in the differential housing.
• Use a needle bearing drift to install the adapter sleeve -1- to the dimension -a- = 2.5 +- 0.5 mm.

Differential, Adjusting

Special tools and workshop equipment required

• Transmission Support -VW353-
• Measuring Set - Magnetic Plate - 50mm -VW 385/17-
• Dial Gauge Holder -VW387-
• Press Plate -VW402-
• Press Piece - Rod -VW408A-
• Press Piece - Multiple Use -3005-
• Press Piece - Bushing -3259-
• Bearing Installer - Wheel Bearing -3345-
• Torque Wrench 1331 5-50Nm -VAG1331-
• -1-Puller - Kukko Internal - 46-56mm -21/7
• -4-Puller - Kukko Counterstay -22/2-
• Dial Indicator -VAS6080A-
• 30 mm dial gauge extension

A New Differential Adjustment Is Required When the following Components Have Been Replaced:

• Transmission Housing
• Clutch Housing
• Differential housing or
• Differential tapered roller bearing

Adjustment Overview.

• Press the outer race/tapered roller bearing with the shim into the clutch housing.

Note

• Pay attention to the shim installed position.
• The collar on the inner circumference faces the seal.

• Press the outer race/tapered roller bearing without the shim into transmission housing.
• Insert differential into clutch housing.
• Mount transmission housing and tighten 5 bolts.
• Press differential in direction of clutch housing and rotate 8 times at the same time.
• Press differential in direction of transmission housing and rotate 8 times at the same time.
• Attach the measuring tools to the transmission housing.
• Set the dial gauge with 1 mm pretension to "0".

1. 30 mm dial gauge extension

• Move the differential up and down and read the play on the dial gauge and note it (example: 0.70 mm).

Determining the Shim

The specified bearing pre-load is obtained by adding a constant pre-load figure of 0.25 mm to the reading obtained.

Example:

• Remove the transmission housing.
• Removing the outer race/tapered roller bearing from the transmission housing

1. Counter Support, for example, Puller - Kukko Counterstay -22/2-
2. Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm -21/7-

• Shim part number. Refer to the Parts Catalog.
• Insert shim with the correct thickness.

The following shims are available:

If the measured shim thickness is larger than those listed in the table, then install two shims that add up to the necessary thickness. Install the thicker shim first.

Tolerance variations make it possible to find the exact shim thickness required.

• Install the outer race again and tighten the transmission housing.

Tightening Specifications

• Transmission housing to clutch housing.

Adjustment Overview

Note

A readjustment of the output shaft for 1st to 4th gears, output shaft for 5th/6th gears and reverse gears or differential is only required if components that directly influence the transmission adjustment, have been replaced. Note the following table to avoid unnecessary adjustments: