39 differential and final drive

DIFFERENTIAL AND FINAL DRIVE 39-1

39 Differential and Final Drive

GENERAL 39-1

MANUAL TRANSMISSION 39-1

Differential and finaldrive assembly (02J) 39-2

Differential and finaldrive assembly (02M) 39-3

Drive flange oil seals, replacing (02J) 39-4

Drive flange oil seal,left side, replacing (02M) 39-6

Drive flange oil seal,right side, replacing (02M) 39-8

AUTOMATIC TRANSMISSION 39-9

Differential and finaldrive assembly (01 M) 39-10

Differential and finaldrive assembly (09A) 39-11

Drive flange oil seals,replacing (01M) 39-12

Drive flange oil seal,left side, replacing (09A) 39-16

Drive flange oil seal,right side, replacing (09A) 39-18

GENERAL

This repair group covers replacement of the drive flange oilseals in the final drive unit. Disassembly of the final drive unitis not covered in this section.

In some cases, the final drive for the automatic transmissionis filled with gear oil. On cars with manual transmission, thefinal drive unit shares the same gear oil as the transmission.For information on checking, draining and filling the manualtransmission and final drive oil, see 0 Maintenance.

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Input ShaftTransmission

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Clutch Engineears: ! I

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Output shaft! Differentialpinion shaft

Final Speedometerdrive drive

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MANUAL TRANSMISSION

~ The layout of the 02J manual transmission and final drive isshown here in relation to the engine and the vehicle's direction of travel (arrows). The 02M transmission adds a sixthgear set, but the layout is similar.

MANUAL TRANSMISSION

39-2 DIFFERENTIAL AND FINAL DRIVE

,~~---14

A39-0166

23. Thrust washer

24. Differential side gear

25. Nut plate• Holds drive flange in position

with bolt (item 17).

26. Differential pinion bevel gearshaft

27. Roll pin

28. Differential small pinion bevelgear

29. Differential large side bevelgear

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17

18

19

20

21

22

29

28

27

26

25

24

23

22

21

20

19

18

17 6 15

19. Spring• Installed behind drive flanges

20. Thrust washer• Install with shoulder toward

spring and tongues to taperedring

21. Tapered ring• With grooves to secure/locate

thrust washer• Install with taper facing differen

tial housing

22. Circlip• Retains tapered ring, thrust

wash.er, and spring when driveflange is removed.

NOTE-Many components shown hererequire transmission disassembly. Those procedures requirespecial tools and skills that areoutside the scope of this manual.

1. Transmission housing

2. Bolt

3. Differential carrier

4. Final drive ring gear

5. Locking plate

6. Nut

7. Shim

16. Drive flange oil seal• See Drive flange oil seals, re

placing (02J).

17. Bolt, socket head• Attaches to nut plate 25• Tighten to 25 Nm (18 ft-Ib)

18. Drive flange

8. Differential carrier bearing, tapered roller bearing outer race

9. Differential carrier bearing, ta-pered roller bearing inner race

10. Differential assembly

11. Speedometer drive gear

12. Differential carrier bearing, tapered roller bearing inner race


14. Transmission clutch housing

15. Sleeve

Differential and final driveassembly (02J)

MANUAL TRANSMISSION


24. Roll pin

25. Differential small pinion bevelgear

26. Nut plate• Holds drive flange in position

with bolt (item 16).

27. Thrust washer

6

5

N39-0725

28. Drive flange, right side• Right and left sides are different

do not interchange.

29. Drive flange oil seal, left side• Right and left sides have differ

ent diameters.• See Drive flange oil seals, re

placing (02M).

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19. Thrust washer<Install with shoulder toward

spring and tongues to taperedring

20. Tapered ring- With grooves to secure/locate

thrust washer• Install with taper facing differen

tial housing

21. Circlip• Retains tapered ring, thrust

washer, and spring when driveflange is removed.

22. Differential large side bevelgear

23. Differential pinion bevel gearshaft



2. Bolt

3. Differential carrier

4. Final drive ring gear

5. Locking plate

6. Nut

7. Transmission clutch housing

8. Shim

14. Shim






15. Drive flange oil seal, right side- Right and left sides have differ

ent diameters.- See Drive flange oil seals, re

placing (02M).

16. Bolt, socket head- Attaches to nut plate (item 26)- Tighten to 25 Nm (18 ft-Ib)

17. Drive flange, left side- Right and left sides are different

do not interchange.

18. Spring-Installed behind drive flanges

Differential and final driveassembly (02M)

MANUAL TRANSMISSION


Drive flange oil seals, replacing (02J)

NOTE-• A slide hammer with a puller hook is needed to re

move the drive flange oil seals. Factory special toolVW771 with attachments is shown in this section. Alternatively, a seal removal tool may be used.

• Several seal installation drifts are also necessary for installing the drive flange oil seals. Factory special tools3106, and 3305 are shown in this section. If using different seal installers, take care to avoid damage to theseal when installing in these hard-to-reach and hardto-see locations.

MANUAL TRANSMISSION

Remove lower sound absorber panels as required to facilitate access.

If replacing the left side drive flange seal, remove the leftside drive axle. See 40 Front Suspension and DriveAxles.

If replacing the right side drive flange seal, turn the steering wheel completely to right (full-lock).

Remove right inner drive axle boot shield (arrows) fromengine, if installed.

~ Unbolt drive shaft(s) (2) at transmission drive flange(s)and secure (tie) up as high as possible.

NOTE-When tying up axle shafts use care not to damage thepaint on the body panels or the axles, or the axle boots.

Place drip tray underneath drive flange(s).

VW771

~-VW771/37

I V39-1961 I


<iii( Install two bolts into CV joint mounting holes of driveflange and counter-hold with a screwdriver. Removesocket head bolt from center of drive flange.

Remove drive flange shaft with spring.

NOTE-Thrust washer may come out with spring.

<iii( Using the slide hammer and appropriate hook or seal removal tool, pullout drive flange oil seal using care toavoid damage to the sleeve.

NOTE-• Do not damage sleeve when removing oil seal.

• If sleeve is damaged, replace as shown.

<iii( If drive flange sleeve is damaged, pry out the old sleevewith a screwdriver and install new sleeve with thrust pad3124, M12 threaded rod from 3066 (A), and an M12 nut(B) and washer. Press sleeve fully into recess.

NOTE-Experience has shown that filling the inside space withgrease where the spring is located prior to installationwill help retain the spring in the correct position.

MANUAL TRANSMISSION


3106

I V39-1962 I

~ To install new seal, drive it fully into the recess with drivertool 3106. Do not tilt seal; drive it squarely into recess.

Fill space between sealing lip and outer lip of oil seal withgrease G052 128 A1.

Install drive flange and spring. Torque socket head bolt tospecification using the reverse of the technique used toremove it.

Install right inner drive axle boot shield on engine if removed.

Install drive shaft(s)

Remainder of installation is the reverse of removal. Besure to top up gear oil, see 0 Maintenance.

Tightening torques

• CV joint to drive flange on transmission,always replace, tighten diagonallyM8 40 Nm (30 ft-Ib)M10 70 Nm (52 ft-Ib)

• Drive axle boot protective shieldto engine block 35 Nm (26 ft-Ib)

• Drive flange to transmission nut plate(socket head bolt) 25 Nm (18 ft-Ib)

Drive flange oil seal,left side, replacing (02M)

MANUAL TRANSMISSION



• A seal installation drift is also necessary for installingthe drive flange oil seals. Factory special tool 3305 isshown in this section. If using different seal installers,take care to avoid damage to the seal when installingin these hard-to-reach and hard-to-see locations.

Remove left front wheel.


Turn the steering wheel completely to the left (full-lock).

~ Unbolt drive shaft (2) at transmission drive flange and secure (tie) up as high as possible.

NOTE-When tying up axle shafts use care not to damage thepaint on the body panels or the axles, or the axle boots.

I N39-1090 I


~ Mark installation position of ball joint bolts (arrows) onleft control arm and remove left control arm bolts.

- Place drip tray underneath drive flange.

~ Install two bolts into CV joint mounting holes of driveflange and counter-hold with a screwdriver. Removesocket head bolt from center of drive flange.

- Remove drive flange shaft with spring.

~ Using the slide hammer and appropriate hook or seal removal tool, pullout drive flange oil seal.

MANUAL TRANSMISSION


MANUAL TRANSMISSION

~ To install new seal, drive it fully into the recess with drivertool 3305. Do not tilt seal; drive it squarely into recess.



Align previously made marks and connect ball joint tocontrol arm with new bolts.

Install drive shaft to drive flange.


Tightening torques


• Ball joint to control armalways replace 20 Nm (15 ft-Ib)

plus 1A turn (90°)• Drive flange to transmission nut plate

(socket head bolt) 25 Nm (18 ft-Ib)

Drive flange oil seal,right side, replacing (02M)



• A seal installation drift is also necessary for installingthe drive flange oil seals. Factory special tool 3158 isshown in this section. If using different seal installers,take care to avoid damage to the seal when installingin these hard-to-reach and hard-to-see locations.

Remove right front wheel.


- Turn the steering wheel completely to the right (full-lock).

Unbolt drive shaft at transmission drive flange.

Place drip tray underneath drive flange.

~ Install two bolts into CV joint mounting holes of drive flangeand counter-hold with a screwdriver. Remove socket headbolt from center of drive flange (left side shown).


4 3 2 1

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I II ~ rI N39-0770 I


Using the slide hammer and appropriate hook or seal removal tool, pull out drive flange oil seal.

"iiiiii( To install new seal, drive it fully into the recess with drivertool 3158. Do not tilt seal; drive it squarely into recess.

- Fill space between sealing lip and outer lip of oil seal withgrease G052 128 A1.




Tightening torques


• Drive flange to transmission nut plate(socket head bolt) 25 Nm (18 ft-Ib)

I N39-0177 I

AUTOMATIC TRANSMISSION

"iiiiii( The general layout of the 01M automatic transmissionand final drive is shown here from the engine (torqueconverter) side. The 09A transmission uses similar principle of operation, but is different in layout and components.

1. Planetary gearing2. Input gear3. Intermediate shaft with pinion gear4. Ring gear and differential



29 33

34. Screw• Install with AMV 185 101 A1

locking fluid• Tighten to 28 Nm (21 ft-Ib)

31. Circlip

32. Gasket/seal

33. Differential cover

~ Final drive oil level checking

• No change interval is specified byVolkswagen. Check regularly asspecified in 0 Maintenance.

• Vehicle should be on a level surface when making the check.

• Remove harness connector andunscrew plastic speedometerdrive to remove.

• Clean dipstick, re-insert and remove to check level.

• Add or top up level as needed.• The difference between "Min"

and "Max" marks on the speedometer drive gear is approx. 0.1liter (3.4 fl. oz.).

• Reinstall speedometer drive gear.• See 37 Automatic Transmission

for appropriate fluid type andquantity.

I V39-1400 I

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24. Bearing support

25. a-ring

26. Output shaft


28. Screw

29. Bearing support lock

30. Circlip



19. Drive flange, left side

20. Compression spring• Installed behind drive flanges

21. Thrust washer• Install over compression spring

22. Tapered ring• Shoulder faces thrust washer

23. Drive flange oil seal, left side• See Drive flange oil seals, re

placing

12. Circlip

13. Center cap

14. Adjusting ring lock

15. Screw

16. Center cap

17. Circlip

18. Dished washer

2. Speedometer drive• Also used as dipstick for mea

suring lubricant level.• See Final drive oil level

checking

3. Output shaft

4. a-ring

5. Adjusting ring

6. Drive flange oil seal, right side• See Drive flange oil seals, re

placing

7. Tapered ring• Shoulder faces thrust washer

8. Thrust washer• Install over compression spring

9. Compression spring• Installed behind drive flanges

10. Drive flange, right side

11. Dished washer

AUTOMA TIC TRANSMISSION

Differential and final driveassembly (01M)

Differential and final driveassembly (09A)




Drive flange oil seals, replacing (01M)



• Several seal installation drifts are also necessary for installing the drive flange oil seals. Factory special tools3106, and 3305 are shown in this section. If using different seal installers, take care to avoid damage to theseal when installing in these hard-to-reach and hardto-see locations.

Removing, right side

<;;;( Remove lower sound absorber panel fasteners (arrows)as required to facilitate access.

<;;;( Remove right inner drive axle boot shield (arrows) fromengine, if installed.

Unbolt right side drive shaft at transmission drive flange.

Position drive shaft up and out of the way as far as possible.

NOTE-If drive shaft can not be positioned in such a way so asto gain sufficient clearance, it will be necessary to remove drive shaft. See 40 Front Suspension andDrive Axles.

Removing, left side

Loosen wheel bolts before raising vehicle.


<;;;( Remove left lower sound absorber panel fasteners (arrows) as required to facilitate access.

Unbolt left side drive shaft at transmission drive flange.

I N37-0674 I



~ Remove pendulum support from subframe (arrows A).

Mark installation position of ball joint bolts (arrows) onleft control arm and remove bolts.

~ Unbolt left stabilizer connecting link (1) from control armand turn connecting link upward. Swing wheel bearinghousing outward and guide left drive shaft (2) out between subframe and transmission.

NOTE-While guiding drive shaft out, it may be necessary tohave an assistant push the engine/transmission assembly forward to allow sufficient clearance.

Lift drive shaft and secure to suspension strut with wireas shown.



3109

VI V39-1411

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Drive flange oil seals, removing,continued for both sides

Pry off cover in center of drive flange by piercing centerof cover with screwdriver.

<iii{ Install fitting tool (3109 shown) and push drive flange inslightly to allow removal of circlip.

NOTE-Volkswagen special tool VW 391 can also be used topress flange in to remove circlip.

Remove dished washer, noting orientation.

<iii{ For CV joint drive axles, mount puller (VW391 shown) todrive flange with two 8x35mm bolts. Install a center spindle with nut through puller that will thread into outputshaft (M10 thread). Turn spindle to press out driveflange.

For triple roller (tripod) drive axles, mount puller (Kukko18-0 shown) to drive flange and pull it off.

NOTE-For both versions, spring, thrust washer and taperedring may drop out of transmission during drive flangeremoval. Be sure to note installation position during reassembly.


Remove drive flange oil seal with seal removal tool (VW681 or equivalent).



o

33/IN39-0061 I

3109

VI V39-1411

\

~ To install new seal, use seal installer 3319 with a lengthof M10 threaded rod approximately 80 mm in long and anM10 nut and washer. Press seal fully into the recess tothe stop. Do not tilt seal; press it squarely into recess.


Install drive flange, dished washer, and circlip.

~ Install fitting tool (3109 shown) and push drive flange inslightly to allow installation of circlip. Install circlip.

NOTE-• Volkswagen special tool VW 391 can also be used to

press flange in to install circlip.

• Place dished washer onto center spindle of puller withconcave side facing in toward the differential.

Install new drive flange center cover.



Tightening torques



plus 1,4 turn (90°)• Connecting link to control arm 25 Nm (18 ft-Ib)• Wheel bolt 120 Nm (89 ft-Ib)• Pendulum mount to body

always replace 20 Nm (15 ft-Ib)plus 1,4 turn (90°)

• Pendulum mount bracketalways replace 40 Nm (30 ft-Ib)

plus 1,4 turn (90°)



Drive flange oil seal,left side, replacing (09A)



• A seal installation drift is also necessary for installingthe drive flange oil seals. Factory special tool T10087is shown in this section. If using different seal installers,take care to avoid damage to the seal when installingin these hard-to-reach and hard-to-see locations.

Loosen wheel bolts before raising vehicle.


~ Remove left lower sound absorber panel fasteners (arrows) as required to facilitate access.

Turn the steering wheel completely to the left (full-lock).

Unbolt drive shaft at transmission drive flange.

N37-0674 I

~ Mark installation position of ball joint bolts on left controlarm and remove bolts (arrows).



<Oiii( Unbolt left stabilizer connecting link (1) from control armand turn connecting link upward. Swing wheel bearinghousing outward and guide left drive shaft (2) out between subframe and transmission.

NOTE-While guiding drive shaft out, it may be necessary tohave an assistant push the engine/transmission assembly forward to allow sufficient clearance.

Lift drive shaft and secure to suspension strut with wireas shown.


<Oiii( Install two bolts into triple roller (tripod) joint mountingholes of drive flange and counter-hold with a screwdriver.Remove socket head bolt from center of drive flange(manual transmission shown).


<Oiii( Using the slide hammer and appropriate hook or seal removal tool, pull out drive flange oil seal.



~ To install new seal, drive it fully into the recess with drivertool T10087. Do not tilt seal; drive it squarely into recess.


Install drive flange and spring.

Apply D 176 404 A2 locking fluid to threads of sockethead bolt. Torque to specification using the reverse of thetechnique used to remove it.

Align previously made marks and connect ball joint tocontrol arm with new bolts.



Tightening torques



plus % turn (90°)• Connecting link to control arm 25 Nm (18 ft-Ib)• Wheel bolt 120 Nm (89 ft-Ib)• Drive flange to transmission


Drive flange oil seal,right side, replacing (09A)



• A seal installation drift is also necessary for installingthe drive flange oil seals. Factory special tool T10088is shown in this section. If using different seal installers,take care to avoid damage to the seal when installingin these hard-to-reach and hard-to-see locations.

~ Remove lower sound absorber panel fasteners (arrows)as required to facilitate access.

Remove right side sound absorber panels.

- Turn the steering wheel completely to the right (full-lock).

- Unbolt right side drive shaft at transmission drive flange.



Position drive shaft up and out of the way as far as possible and secure.


-( Install two bolts into triple roller (tripod) joint mountingholes of drive flange and counter-hold with a screwdriver.Remove socket head bolt from center of drive flange(manual transmission shown).


-( Using the slide hammer and appropriate hook or seal removal tool, pull out drive flange oil seal.

-( To install new seal, drive it fully into the recess with drivertool T10088. Do not tilt seal; drive it squarely into recess.


Install drive flange and spring.

- Apply 0 176 404 A2 locking fluid to threads of sockethead bolt. Torque to specification using the reverse of thetechnique used to remove it.





Tightening torques



plus 1A turn (90°)• Connecting link to control arm 25 Nm (18 ft-Ib)• Wheel bolt 120 Nm (89 ft-Ib)• Drive flange to transmission


NOTE-• Volkswagen part numbers for fluids, oils, and chemi

cals are given for reference only! Always consult withyour local Volkswagen Parts Department or aftermarket Parts Specialist for the latest parts information.

• For appropriate fill capacities and fluid specifications,see 0 Maintenance, 34 Manual Transmission, and37 Automatic Transmission.


39 differential and final drive

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