Volkswagen Golf Variant 2007 Service Manual page 203

Removing spring pin without circumferential groove (long spring
pin); pressing out differential pinion pin
When pressed out, spring pin will be sheared off.
– Drive remainder of spring pin out of differential cage and dif‐
ferential pinion pin.
Installing spring pin without circumferential groove (long spring
pin)
– Align hole in differential pinion pin with hole in differential cage.
– Drive in new spring pin with drift -1- until dimension -a- =
3.0 mm is attained.
• The spring pin must not come in contact with gears with dif‐
ferential cage installed.
In some gearboxes, the one-piece thrust washer has a shoulder
-A- near the holes.
In this case, the differential cage has a circumferential groove
-B-.
– Lubricate one-piece thrust washer with gear oil and install.
– Install one-piece thrust washer so that it engages in groove
-B- in differential cage.
Installing differential bevel gears and differential pinion pin
– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
Installation position: shoulder to sun gear
– Drive differential pinion pin into final position and secure with
spring pin.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
199
3. Differential