Center Differential, Servicing

Center differential, servicing





The items illustrated in the following illustrations can be removed with the transmission installed.
1. Allen head bolt, 23 Nm
2. Rear flange shaft
3. Oil seal
- For rear flange shaft, -item 2
- Replace
4. Bolt, 23 Nm
- For housing cover, -item 5
- Qty. 4
5. Housing cover
- With vibration damper
6. O-ring
- Coat with gear oil
7. Circlip
- For ball bearing -item 8 on gear 1-item 9-
8. Grooved ball bearing
- For gear-1 -item 9
- Pressing off see Fig. 1
- Pressing on see Fig. 2
9. Gear-1
- For rear drive pinion set
- If damaged, replace together with gear 2-item 17- only
- To remove and install, pull together with -item 7 and 8 -to the rear out of center differential housing -item 13
10. Circlip
- For needle bearing -item 11 -
11. Needle bearing
- For gear-1 -item 9
- Remove to replace only
- To replace, heat center differential housing -item 13 to approximately 100°C and use a drift to drive needle bearing out to the rear
- Drive in onto stop with sleeve 30-21
12. Bolt, 23 Nm
- Loosen and tighten gradually and diagonally
13. Center differential housing
14. Tensioning nut
- For rear flange shaft, -item 2 -
15. Needle roller bearing
- For gear-2 -item 17
- Remove to replace only
- Replace
16. Circlip
- To secure needle bearing, -item 15 in center differential housing -item 13
17. - Gear-2
- For rear drive pinion set
- If damaged, replace together with gear 1 -item 9 only
- To remove and install, pull together with -item 18, 19 and 23 to the rear out of center differential housing -item 13
18. Grooved ball bearing
- For gear-2 -item 17
- Press off
- Press on
19. Circlip
- To secure grooved ball bearing, -item 18 in center differential housing -item 13
20. Washer
- For grooved ball bearing -item 18
- Clip guide plate -item 21 -in position, before installing
21. Guide plate
22. Bolt, 10 Nm
23. Circlip
- To secure grooved ball bearing -item 18 onto gear-2 -item 17
24. Gasket
25. Torsen differential (PAT)
- Replace complete if damaged
26. Oil seal
27. Magnet
28. Dowel pin
- Qty. 2
29. Breather
- For center differential
- With cover attached
- Installation position: Breather must project 10 to 11 mm from housing without cover
30. Bolt, 23 Nm
31. Intermediate - flange for front final drive
32. Gasket
33. Dowel sleeve
34. Drive pinion
- For front final drive
35. Intermediate - pinion
- For front final drive
- Installation position: Gear marking points to center differential
36. Drive pinion
- For front final drive
- Installation position: Gear marking points to center differential
37. Oil seal





- Fig. 1 Pressing off grooved ball bearing for gear-1





- Fig. 2 Pressing on grooved ball bearing for gear-1





- Fig. 3 Pressing off grooved ball bearing for gear-2





- Fig. 4 Pressing on grooved ball bearing for gear-2

Center differential, removing and installing
- Observe general repair instructions.

Special tools and equipment





- VAG1331 Torque wrench





- VAG1383A Engine/transmission jack

Removing
- Remove front exhaust system with catalyst.





- Remove heat shield -A- from vehicle underbody.
- Remove cover plate -B- (arrows).
- Disconnect driveshaft from transmission.
- Support transmission from below with transmission jack VAG1838 A and the respective plate 1359/2.





- Remove bolts -B-.
- Remove heat shield -C-.





- Remove transmission mount -D- or-H-.
The left and right-hand -E- transmission supports remain on transmission.
- Place VAG1306 Drip tray underneath.
- Drain gear oil in center differential.





- Loosen bolts -A and C- for center differential housing -2- using diagonal sequence and remove.
- Do not loosen bolts -B-.
Pull center differential housing carefully to rear off transmission, otherwise the Torsen differential will fall out of the transmission.





- Pull Torsen differential to rear off output shaft.

Installing
Install in reverse order but note following:





- Check dowel pins -arrows A and arrow Bare installed.
- Install gasket.
- Install cleaned magnets in the cast retainer 1- in intermediate flange.





- Install Torsen differential onto output shaft splines and drive pinion of front gear wheel, rotate item slightly when doing this.
- Check that installed Torsen differential can be turned by hand.





- Install center differential housing complete with installed gears and rear flange shaft onto transmission flange.
- Insert bolts -A- and -C- for center differential housing -2- and tighten to torque setting incrementally using diagonal sequence.
- Install left and right-hand transmission brackets.
- Connect driveshaft.
- Install front exhaust system with catalyst.
- Fill center differential with gear oil and check.