Audi Workshop Service and Repair Manuals

Exploded view - dismantling and assembling differential

Special tools and workshop equipment required

t	Drift -VW 295-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Press tool -VW 442-

t	Press tool -40-21-

t	Thrust plate -40-105-

t	Thrust piece -2050-

t	Drift -3138-

t	Torque wrench -V.A.G 1332-

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

t	Adapter -V.A.G 1582/6-

t	Puller -Kukko 44/2-

Heat tapered roller bearing inner races to 100°C before installing.

Always renew both tapered roller bearings together.

The differential must be adjusted → Chapter if the tapered roller bearings, differential cage, rear final drive cover, final drive gear set or the final drive housing are renewed.

Clamp rear final drive in assembly stand → Fig.

1)	Adjustment work is required if these components are renewed → Chapter

1 -	Cover for rear final drive → Note

2 -

O-ring

q	Always renew

q	Lubricate with oil when installing

3 -	Rear final drive housing → Note

4 -

Shim S1

q	Note thickness

q	Table of adjustments → Chapter

5 -	Small tapered roller bearing outer race → Note

q	Driving out → Fig.

q	Pressing in → Fig.

6 -	Small tapered roller bearing inner race → Note

q	Pulling off → Fig.

q	Pressing on → Fig.

7 -	Hexagon bolt, 60 Nm then turn 45° further

q	Always renew

q	Lightly tighten bolts then tighten in diagonal sequence to correct torque

q	For correct version, refer to → Electronic parts catalogue

8 -	Differential cage → Note

9 -	Crown wheel → Note

q	Is paired with pinion shaft (final drive gear set)

q	Drive off with a drift → Fig.

q	Fitting on differential cage → Fig.

q	For correct version, refer to → Electronic parts catalogue

10 -	Spring pin

q	For securing differential pinion pin

q	Drive in flush

11 -	Large tapered roller bearing inner race → Note

q	Pulling off → Fig.

q	Pressing on → Fig.

12 -	Large tapered roller bearing outer race → Note

q	Driving out → Fig.

q	Pressing in → Fig.

13 -

Shim S2

q	Note thickness

q	Table of adjustments → Chapter

14 -	Threaded piece

15 -

Sun wheel

q	Installing → Fig.

q	Adjusting → Fig.

16 -	Planet pinion

q	Installing → Fig.

17 -	Differential pinion pin

q	Drive out with drift

18 -

Shim

q	Determining thickness → Fig.

19 -	Thrust washer

q	Check for cracks

Clamping rear final drive to assembly stand

Driving small tapered roller bearing outer race out of housing –  After removing, check shims for damage.

Pressing small tapered roller bearing outer race into housing (press onto stop)

Pulling off small tapered roller bearing inner race A - Commercially available two-arm puller, e.g. puller -Kukko 44/2-

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

Pulling off large tapered roller bearing inner race –  Before setting up the puller, place thrust plate -40-105- on differential cage.

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

Driving tapered roller bearing outer race out of cover –  After removing, check shims for damage.

Pressing tapered roller bearing outer race into cover

Driving crown wheel off cage

Installing crown wheel   WARNING Wear protective gloves. –  Heat crown wheel to approx. 100°C and install. –  When fitting crown wheel, use centralising pins -A- (shop-made tool) to locate.

Installing differential bevel gears –  Shim thicknesses must be re-determined if sun wheels have been renewed → Fig.. –  Install sun wheels with correct shims (as measured). –  Insert planet pinions (spaced 180° apart) and pivot into position -arrow-. –  Fit and align thrust washers. –  Insert threaded pieces, ensuring they are seated correctly. –  Drive differential pinion pin into final position and secure.

Adjusting differential bevel gears –  Insert sun wheels with 0.5 mm thick shims. –  Insert planet pinions with thrust washers (spaced at 180°). Ensure that the thrust washers are not interchanged from this point onwards. –  Drive in differential pinion pin. –  Press planet pinions outwards. –  Press sun wheels in direction of -arrows- and check the amount of play. –  Determine the thickest shim that can still just be fitted for the sun wheels on each side. –  Select shims of equal thickness. Table of shims

Shim thickness (mm)
0.50	0.70	0.90
0.60	0.80	1.00

Select correct shims from → Electronic parts catalogue.

If there is no measurable play and the bevel gears can just still be turned, the adjustment is acceptable.