Differential Pinion Gears and Side Gears
In production, the differential pinion shaft is pressed in place during assembly. If the shaft or gears are removed and replaced, circlips must be installed to secure the shaft. The differential pinion shaft and the pinion and side gears are available as individual replacement parts. They are also available as a complete set, Volkswagen part no. 020 498 081 A.
NOTE-
Part numbers are for reference only. Always rely on an authorized Volkswagen parts department for the most accurate and up-to-date parts information.
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To replace:
| 1. | Remove the drive flange shaft circlips and remove the drive flange shafts. |
| 2. | Drive the differential pinion shaft out of the differential and remove the pinion and side gears, and the one-piece thrust washer. |
| 3. | Lubricate the thrust washer with transmission oil, then install the washer, the pinion gears, the side gears and the differential pinion shaft. Secure the shaft using new circlips at each end. |
| 4. | Install the drive flange shafts. |
| 5. | Adjust the shafts by pressing them against the differential pinion shaft while pressing the side gears against the differential housing, then install the circlips. See Fig. 8-5. Use the largest circlip that does not jam the side gears. Two different size circlips are available. One is 2.0 mm thick, part no. 020 409 299. The other is 2.3 mm thick, part no. 020 409 299 A. |
| Fig. 8-5. | Cutaway view of differential showing circlip (arrow) used to adjust drive flange shafts. |
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