Gearbox diff bearing replacement - part 1

[muddyboots]

As some may remember, the diff bearings are failing in my Passat's gearbox, so I bought another old box with the same symptoms (for £46) to repair. Then my local garage will fit it for me at the same time as changing the clutch.

Seeing the costs of recon'd boxes is what tempted me to give this a whirl.

It's a 6-speed FRK gearbox from a 2002 PD130 TDI Sport.

First driveshaft hub coming out:


Second driveshaft hub out, revealing the diff cover plate and vehicle speed sensor:


Diff cover plate coming off:


Here's the diff complete with bearings, it just lifts straight out:


The n/s bearing, with speed sensor ring in front:


Close ups of o/s bearing, does anyone know if this looks worn ?
(Images too big to embed with IMG tags, you'll have to click the links)
http://farm6.static.flickr.com/5222/556 ... 80da_o.jpg
http://farm6.static.flickr.com/5108/556 ... 848a_o.jpg

N/s bearing...
(Images too big to embed with IMG tags, you'll have to click the links)
http://farm6.static.flickr.com/5269/556 ... 3b12_o.jpg
http://farm6.static.flickr.com/5177/556 ... c0ed_o.jpg

Inside the diff housing:
(Clutch/bellhousing is to left, input shaft runs across top into main gearbox, output shaft emerges from the right)


Closeup of output shaft:
(Images too big to embed with IMG tags, you'll have to click the link)
http://farm6.static.flickr.com/5024/557 ... 034e_o.jpg

My makeshift workshop!