Audi Workshop Service and Repair Manuals

Modified gearbox housing and tapered roller bearings for differential from gearbox build date 06 05 2 onwards Special tools and workshop equipment required

t  Thrust plate -VW 402-

t  Press tool -VW 412-

t  Installing sleeve -VW 455-

t  Spacer sleeve -VW 472/2-

t  Tube -30-14-

t  Thrust plate -30-205-

t  Press tool -40-21-

t  Thrust piece -3002-

t  Tube -3259-

t  Puller -V.A.G 1582-

t  Adapter -V.A.G 1582/3-

t  -1-Internal puller 46...58 mm, e.g. -Kukko 21/7- t  -4-Counter support, e.g. -Kukko 22/2-

From gearbox build date 06 05 2 onwards, tapered roller bearing on gearbox housing side is enlarged. The following components are affected: t  -A- Tapered roller bearing inner race    Removing: → Fig.    Installing: → Fig. t  -B- Tapered roller bearing outer race    Removing: → Fig.    Installing: → Fig. t  -C- Shim “S1” t  Bearing seat for tapered roller bearing outer race -arrow- in gearbox housing

t  Bearing seat for tapered roller bearing on differential    Dimension -a- enlarged from 38 mm to 41 mm. –  Select correct version of all components from → Electronic parts catalogue.

Pulling off tapered roller bearing inner race –  Before fitting puller, position spacer sleeve -VW 472/2- and thrust piece -3002- on differential cage.

Pressing on tapered roller bearing inner race –  Use press tool -40-21- to press on tapered roller bearing inner race as far as stop. –  Support opposite side of inner race using installing sleeve -VW 455-.

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 46 ... 58 mm, e.g. -Kukko 21/7-

Pressing outer race for tapered roller bearing into gearbox housing –  Fit shim S1, always 1 mm thick, under outer race. –  Press in tapered roller bearing outer race as far as stop using thrust plate -30-205-. –  Support gearbox housing with tube -3259- and tube -30-14- directly below bearing mounting.

Modification of one-piece thrust washer and differential cage On some gearboxes, the one-piece thrust washer has a projection next to the holes -A-. In this case the differential cage has a corresponding annular slot -B-. –  Lubricate one-piece thrust washer with gear oil and install. –  Position one-piece thrust washer so that it engages in the slot -B- in the differential cage.