Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary equipment required

• ◆ Multi-purpose tool VW 771
• ◆ Socket 3257
• ◆ Internal puller Kukko 21/3

Notes:

• ◆ Removing and installing is possible with the gearbox installed.
• ◆ The differential can be removed and installed without removing selector mechanism, input shaft, drive pinion and gear box cover. These components must be removed if the differential needs to be adjusted.
• ◆ Flange shaft may be with or without a polygon bearing. Allocation .
• ◆ The polygon bearings can only be replaced together with the flange shaft.
• ◆ Inspect polygon bearings for visible damage.

• ◆ If the polygon bearings do not run smoothly with the flange shaft removed, this does notindicate that the bearings are defective. A test for noisy bearings can only be performed with the bearings installed.
• ◆ A spacer ring is fitted between the polygon bearing and the differential large bevel gear on flange shafts with 30 mm spline diameter => Fig.4, -Item 5-.
• ◆ Adjustments are required when replacing components marked1) => adjustment overview, Page 39-39.

• Gearbox housing 1)
• ◆ Housing manufactured from aluminium or magnesium => Page 34-85
• ◆ Aluminium version: must only be fitted to an aluminium gearbox cover
• ◆ Magnesium version: must only be fitted to a magnesium gearbox cover
• Sealing ring
• ◆ Replacing => Page 39-2.
• Circlip
• ◆ Replace
• ◆ Removing and installing => Fig. 1

• Spacer ring
• ◆ Is only fitted on flange shafts with polygon bearing which have a spline diameter of 30 mm => from Page 00-3
• ◆ Removing =>Fig.2
• ◆ Installing => Fig. 3
• Flange shaft
• ◆ Removing and installing
  => Page 39-2
• ◆ Assembling flange shaft with polygon bearing => Fig.4
• Differential with crown wheel 1)
• ◆ Can be removed without removing gear cluster
• ◆ Dismantling and assembling => Page 39-21
• ◆ From 08.98 ä Reinforcements (phased introduction) => Fig.7

• Cover for final drive 1)
• ◆ Aluminium version: must only be fitted to an aluminium gearbox housing
• ◆ Magnesium version: must only be fitted to a magnesium gearbox housing
• ◆ Identification =>Fig.5
• ◆ From 08.98 ä Reinforcements (phased introduction) => Fig.7
• ◆ Allocation

=> Parts List

• ◆ Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces

• TORX-screw - 25 Nm
• ◆ For aluminium gearboxes: black, M8 x 42, without washer
• ◆ For magnesium gearboxes ä approx. 09.97: bright metal, M8 x 45, fit washer with each bolt
• ◆ For magnesium gearboxes 09.97 ä (phased introduction): bright metal, different bolt lengths=> Fig.6
• Speedometer drive wheel
• ◆ Removing and installing
  => Page 39-8
• ◆ Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use excessive force - the drive wheel can break easily

→ Fig.1    Removing and installing circlip

• ‒ Clamp flange shaft in vice using soft jaws. Use new circlip -A- to press out old circlip from groove in flange shaft.

→ Fig.2    Removing spacer ring

•     A -    Internal puller 18.5 ... 23.5 mm, e.g. Kukko 21/3

• ‒ If the spacer ring is tight pull out using the multi-purpose tool VW 771.

→ Fig.3    Installing spacer ring

• ‒ Drive new spacer ring home, when doing this take care not to cant ring.

→ Fig.4    Assembling flange shaft with polygon bearing

•     1 -    Flange shaft
•     2 -    Needle roller bearing (polygon bearing)
•     3 -    Spacer ring
•     4 -    Circlip
•     5 -    Spacer ring - fitted additionally on shafts with 30 mm spline diameter

Note:

The needle roller bearings (polygon bearings) do not turn easily when the flange shaft is removed. This does not indicate a faulty bearing.

→ Fig.5    Differential cover identification

The inscription >Mg Al 9 Zn 1< can be found in the vicinity of the arrow on gearboxes made of magnesium.

Mg = magnesium; additional data for production purposes.

→ Fig.6    Allocation of bolts in differential cover, gearboxes with magnesium housing from approx. 09.97 ä

•     1 -    Bright metal bolts, M8 x 42 without washer
•     2 -    Bright metal bolts, M8 x 45 with captive washer

Note:

Only M8 x 45 bolts with captive washers are supplied as replacement parts; if necessary these can be used for all securing bolts on the gearbox cover.

→ Fig.7    Reinforcements introduced from 08.98 ä (taper roller bearings with larger inner and outer diameters) on the left-hand side of the differential (crown wheel side). The introduction is phased from gearbox build date 17 08 8, but covers all gearboxes from build date 11 01 9.

The following components are affected by this modification:

1 - Differential housing

2 - Taper roller bearing inner race

3 - Taper roller bearing outer race

4 - Shim "S1"

5 - Final drive cover

Part allocation:

=> Parts List