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  Topic Review (Newest First)
6 Days Ago 11:24 AM
tditoronto Great job!
4 Weeks Ago 08:01 PM
pilot60378 Update: the diff is doing great, no problems whatsoever. I also replaced fluid in center and rear diffs not that they have been a problem. Next was the driveshaft center support bearing. Mine was cracking but not separated, thank the lord! After replacing that, the only issue now is the tranny. I think I'll let that seeping dog lie for a while.
05-15-2019 01:15 PM
Gnits Most Touaregs don't have front locking diff, only some of the highest specced ones. Then again, a lot of Touaregs don't have locking rear differential either, and it's only the central differential that's lockable on them.
05-15-2019 12:54 PM
VD-CH Great write-up!

But... Euh... am I the only one to have read "front locking diff" and be surprised?!
05-07-2019 04:50 PM
TRespect Like Nooby said BLOODY HELL
Thanks for sharing.
I have a 2004 bought at 128.000km, is now 136.000km and no signs of any diff issues. Hope I won't need to follow your steps anytime soon
04-26-2019 05:57 AM
pilot60378 Thanks for the kind words Dragline! Looking back on it I think it would've been better to get the extra pinion bearings and grind the i.d. on those to slip on the pinion rather than grind the pinion itself. However I haven't had any problems thus far which I'm happy about. If someone is worried about having to go to a shop again to press the outer pinion bearing on, don't sweat it, I have an "old school" trick for you.

The first time I rebuilt the diff I didn't press the outer bearing on. Instead, take the pinion and put it in the freezer for a few hours. Next heat up your oven to around 250-300F. Tell the wife you're making VW cookies lol. Put the bearing in the oven for about 30mins. Don't worry, the heat won't hurt the bearing at all at that temperature. Get an oven mitt to hold the bearing and in the proper orientation. Make sure the pinion shims are in place on the shaft first!! Now take that pinion out of the freezer and slip that bearing on. There's enough expansion on the bearing and enough contraction on the pinion shaft for the bearing to just fall in place. Voila! No press needed! Just remember, it's a "one shot" deal.

Now to deal with a bad center support bearing on the driveshaft!
04-25-2019 08:53 AM
dragline1570 Pilot what a superb write up. and thank you for your kind words about by conversation with you.

I would be there for a week to write half that.

Pilot has shamed me and from now on i will be using a fixed spacer instead of modifying the factory spacer.

As and addition to those who would like to go down the fixed spacer route (collapsible spacers are really only used for ease of mass production assembly) i put forward this drawing.

It will be my method for calculating the fixed spacer length on future rebuilds.

A pain to make for a one off build but Pilot went to such great lengths to ensure he had the best setup diff possible and thought this may or may not have made it easier.

Polishing down the pinion so the bearings slip on and off easily is a great idea but only really needs to be done on the pinion end journal.
The tail shaft end bearing on the pinion can be pressed apart after checking setup easily and it is not that tight.
On final assembly for the bearing on the polished journal i would use some loctite to ensure it doesn't spin on the shaft. This can be done easily.

Again Pilot kudos

04-22-2019 01:44 PM
pilot60378 One tip I want to mention is when installing the carrier into the housing, install the driver side axle tube first with the one torx bolt but leave it slightly loose. That allows the carrier to be supported enough to keep it from falling out of the housing and enough room that you won't have to force anything into the housing. Another thing I forgot to add is Dorman has an axle nut that will work for the pinion nut if it gets messed up by using the impact gun. Dorman part # 615-091.1 is a 22mm x 1.5 axle nut at a very good price. Autozone sells it for $3.99.

If someone ends up having to get some things made at a machine shop, you're going to spend some money for it. However, I guarantee after paying for everything, you'll still be well under the cost of a re-manufactured unit from VW. I know if that was my only option, I'd sell the Treg as the value of it is not worth purchasing a unit from VW. I wish I took more pictures but I hadn't originally planned on posting all of this.

I've read so many posts about rebuilding the front diff where folks got frustrated and only carrier bearings are replaced etc etc. I figured this might help everyone that wants to rebuild or have the diff rebuilt completely and give them an option. When there's a will, there's a way! If the admins feel so inclined, sticky this as a DIY. I am, however, no expert on diffs but doing as much research as I have I feel confident on my procedure. Like I said before, none of this would have even been possible without Dragline1570. Thanks Mark!
04-22-2019 09:53 AM
Gnits Great writeup, even though I hope I'll never need it
04-22-2019 07:46 AM
2005 Touareg Pilot, Thank you for your reply and for this outstanding write-up.
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