Teardown Page 3

With the shafts out of the way, the differential can now be lifted out of the case....

You can see the damage on the inside of the case in places from the metal being spun around inside by the ring gear, and you can see the very silver colored oil...

Remove the input shaft ball bearing using a bearing splitter as shown...

You can now lift off 4th gear and the synchronizer ring to expose the large circlip that holds the 3rd/4th sync hub onto the input shaft...

Remove the circlip, it is fairly large and stiff, so it can be tricky to get a good grip on...

With the circlip removed, you can now press 3rd gear, and the 3rd/4th sync hub and collar from the shaft. The plate shown is VW402 and has a round section with a lip that 3rd gear fits into...

Here is the 3rd gear needle bearing, it is split, and needs spread open to be lifted up and off of the shaft. I've got the shaft mounted in a vise with soft jaw inserts so I could hold the bearing open and take the pic...

That leaves the input shaft stripped and bare, and the output shaft has only the taper bearings pressed onto it.

Use a bearing splitter as shown to remove the taper bearings from the output shaft...

To remove the diff bearings, you can use a bearing splitter as shown with the output shaft bearings above, or the VAG1582 bearing puller can be used.

The end clamps over all of the rollers at once, and locks itself onto the bearing without damaging the bearing or cage....

Here you find the cause of all the damage we've seen so far. One missing rivet head. The head then was spun around and started destroying things. Often times the rivet or broken piece of gear get spit through the case or are spun around until several holes are machined around the diff area from the inside out. This is commonly called SMS or Self Machining Syndrome.

The small rivets can fail as shown, or the cross shaft, which is secured with clips on this example, could also cause the large-head rivet on each side of the shaft to be damaged from the shaft smacking into it. When the large-head rivet is gone, the rivet head can do the same damage as shown here, but the shaft can float out and knock a hole in the case as well.

Some trans have rivets only, some have rivets and circlips on the shaft, some shafts are secured with a roll pin, but they all use rivets, and can fail as shown here.

I'm not covering the tear down of the differential just yet, when I get the pics for it, I'll update this page or make another.

The case halves can now be stripped of their bearings and races, click here to go to page 4.