Audi Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Tube -VW 418 A-

t	Press tool -VW 454-

t	Installing sleeve -VW 455-

t	Spacer sleeve -VW 472/2-

t	Thrust pad -VW 510-

t	Tube -30 - 14-

t	Tube -2040-

t	Thrust piece -3002-

t	Counterhold tool -3067-

t	Tube -3259-

t	Wheel bearing tube -3345-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t	-1- Kukko internal puller 21/7

t	-4- Kukko 22/2 counter-support

t	Thrust plate -30 - 205-

t	Press tool -40 - 21-

t	Torque wrench -V.A.G 1331- (5 ... 50 Nm)

t	Adapter -V.A.G 1582/3-

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 –  Check whether a shim S1 must be inserted underneath outer race → Fig.. –  If necessary, fit shim S1 (always 1 mm thick) under outer race. –  Support gearbox housing with tube -3259- directly below bearing mounting.

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   WARNING Wear protective gloves. –  Heat tapered roller bearing inner race to approx. 100°C before pressing on. –  Support opposite side of inner race using installing sleeve -VW 455-. Shoulder of installing sleeve -VW 455- points to differential cage.

Pressing tapered roller bearing outer race -A- out of clutch housing B -  Internal puller 46...58 mm, e.g. -Kukko 21/7- –  Clamp internal puller firmly under tapered roller bearing outer race.

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with tube for wheel bearing -3345- directly below bearing mounting.

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   WARNING Wear protective gloves. –  Heat tapered roller bearing inner race to approx. 100°C before pressing on.

Pressing out differential pinion pin The spring pin is sheared off when pressing out. –  Drive the remaining part of the spring pin out of the differential cage.

Installing differential bevel gears –  Lubricate one-piece thrust washer with gear oil and install. –  Install both sun wheels and secure (e.g. with flange shaft). –  Insert planet pinions (180° apart) and pivot into position. –  Push differential pinion pin -arrow A- in as far as first planet pinion. –  Fit threaded pieces -arrows B- in sun wheels. –  Drive differential pinion pin into final position and secure with spring pin.