Disassembling And Assembling The Differential (Transmission G 86): Tools

Fig 1: Identifying Special Tools

Courtesy of PORSCHE OF NORTH AMERICA, INC.

SPECIAL TOOLS

Item	Designation	Special tool
A(1)	Pressure piece	VW 472/1
B(1)	Pressure piece	P263
C(1)	Pressure disc	VW 511
D(1)	Pressure piece	2050
E(1)	Drive-in mandrel	VW 295
(1) Fig 1 .

Fig 2: Exploded View Of Differential Assembly (Transmission G 86)

Courtesy of PORSCHE OF NORTH AMERICA, INC.

DIFFERENTIAL COMPONENT DESCRIPTION CHART (TRANSMISSION G 86)

No.	Designation	Qty.	Removal	Installation
1	Speedometer-drive gear	1(2)
2(2)	Tapered roller bearing inner race (1)	1	Remove with commercially available two-arm puller and special tool P 263	Heat to approx. 100°C, put into position and press again after heat exchange
3(2)	Tapered roller bearing inner race (1)	1	Same as No. 2	Same as No. 2
4(2)	Crown wheel screw	10		Always replace. The thread must be dry and grease-free. Tighten crosswise with 60 Nm (44 ft.lb) and then continue turning with a rotational angle of 45°C.
5(2)	Crown wheel (1)	1	Force off with a mandrel through the threaded holes	If required, heat up to approx. 100°C
6(2)	Dowel pin	1		Drive in the correct position
7(2)	Axle	1
8(2)	Differential bevel gear (small)	2
9(2)	Differential bevel gear (large)	2
10(2)	Thrust washer assembly	1		Insert with gear oil
11(2)	Differential housing (1)	1
12(2)	Tapered roller bearing outer race	1	Drive out using a suitable aluminum or copper mandrel (phi 6...8 mm)	Press in with special tools VW 511 (or 2050) and VW 295
13(2)	Adjusting shim "S1"	X	Note the thickness for installation	Remeasure the thickness if necessary
14(2)	Cover for final drive (1)	1		Seal with Loctite 574
15(2)	Tapered roller bearing outer race	1	Same as No. 12	Drive in with special tool VW 472/1
16(2)	Adjusting shim "S2"	X	Same as No. 13	Same as No. 13
17(2)	Transmission housing (1)	1
(1) If the parts are replaced, readjustment is necessary (2) For explanation see Fig 2