Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary equipment required

• ◆ Drift VW 295
• ◆ Thrust plate VW 401
• ◆ Thrust plate VW 402
• ◆ Press tool VW 407
• ◆ Press tool VW 408 A
• ◆ Thrust pad VW 447 H
• ◆ Thrust pad VW 447 i
• ◆ Thrust piece VW 472/1
• ◆ Thrust pad VW 511 i
• ◆ Thrust plate 30-11
• ◆ Thrust plate 30-205
• ◆ Sleeve 40-21

• ◆ Thrust plate 40-105
• ◆ Drift 3138
• ◆ Sleeve 3144
• ◆ Tube 3296
• ◆ Sealant AMV 188 000 02 or AMV 188 001 02
• ◆ Two-arm puller Kukko 20/10 or Kukko 44/2
• ◆ Two-arm puller Kukko 204/2

Notes:

• ◆ Removing and installing differential .
• ◆ Replace both taper roller bearings together.
• ◆ Adjustments are required when replacing components marked 1) => adjustment overview, Page 39-44.

• Gearbox housing 1)
• Shim "S2"
• ◆ Note thickness
• ◆ Adjustment overview => Page 39-44
• Outer race for taper roller bearing (right) 1)
• ◆ Tapping out => Fig.1
• ◆ Driving in with VW 472/1 and VW 408 A => Fig.2
• ◆ With letters CPU, CXF and CXZ with VW 295 and 30-205

• Inner race for taper roller bearing (right) 1)
• ◆ Pull off with 3296 => Fig.3
• ◆ Pressing on =>Fig.4
• ◆ With letters CPU, CXF and CXZ with thrust sleeve 40-21
• Crown wheel 1)
• ◆ Paired with pinion shaft (final drive set)
• ◆ Allocate according to the gearbox code letters via the Parts Catalogue => Page 00-3.
• ◆ Drive off housing with a drift => Fig.10
• ◆ Fit to differential housing => Fig.11

• Differential housing 1)
• ◆ Allocate according to the gearbox code letters via the Parts Catalogue => Page 00-3.
• ◆ From 08.98 ä Reinforcements (phased introduction) => Page 39-24 Fig.5
• Bolt - 60 Nm + turn 45ofurther
• ◆ Replace
• ◆ Lightly tighten bolts then tighten diagonally to specified torque.
• Inner race for taper roller bearing (left) 1)
• ◆ Pulling off =>Fig.5
• ◆ Press on with 3296 => Fig.4
• ◆ With letters CPU, CXF and CXZ with thrust sleeve 40-21
• ◆ From 08.98 ä Reinforcements (phased introduction) => Page 39-24 Fig.5

• Speedometer drive wheel
• ◆ Removing and installing => Page 39-15
• ◆ 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
• Outer race for taper roller bearing (left) 1)
• ◆ Tapping out => Fig.7
• ◆ Driving in with VW 472/1 and VW 408 A => Fig.8
• ◆ With letters CPU, CXF and CXZ with VW 511 and VW 295
• ◆ From 08.98 ä Reinforcements (phased introduction) => Page 39-24 Fig.5
• ◆ Driving in with 2050 and VW 408 A => Fig.9
• ◆ Allocation

=> Parts List

• Shim "S1"
• ◆ Note thickness
• ◆ Adjustment overview => Page 39-44
• ◆ Allocation

=> Parts List

• Cover for final drive 1)
• ◆ From 08.98 ä Reinforcements (phased introduction) => Page 39-24 Fig.5
• ◆ Allocation

=> Parts List

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

• Large bevel gear
• ◆ Installing => Fig. 12
• Shaft for planet wheels
• ◆ Knock out with drift after removing spring pin

• Spring pin
• ◆ For securing shaft for bevel gears
• ◆ Version with annular groove: Removing and installing => Fig.13
• ◆ Version without annular groove: Drive out with drift
• Small bevel gear
• ◆ Installing => Fig.12
• One-piece thrust washer
• ◆ Coat with gearbox oil when installing

→ Fig.1    Driving right taper roller bearing outer race out of gearbox housing

• ‒ Turn webs -A- and -B- out until they sit on the outer race within the recess in the gearbox.
• ‒ After removing check shims for damage.

→ Fig.2    Driving right taper roller bearing outer race into gearbox housing

• ‒ Thrust piece VW 472/1 is fitted with the taper in the outer race.

Note:

With letters CPU, CXF and CXZ, thrust plate 30-205 and drift VW 295 must be used.

→ Fig.3    Pulling off right taper roller bearing inner race

•     A -    Two arm puller, e.g. Kukko 20/10 or Kukko 44/2

Notes:

• ◆ If using a puller with small diameter spindle, also fit thrust plate 30-11 between thrust pad 447 H and puller.
• ◆ With letters CPU, CXF and CXZ, thrust plate 40-105 must be used.
• ◆ There is a slot in the bearing seat in the differential housing for applying puller -A-.

→ Fig.4    Pressing on right taper roller bearing inner race

• ‒ Heat the inner race to approx. 100 oC, position and push to final position.

Note:

With gearbox code letters CPU, CXF and CXZ, thrust sleeve 40-21 must be used.

→ Fig.5    Pulling off left taper roller bearing inner race

•     A -    Two arm puller, e.g. Kukko 204/2

Notes:

• ◆ If using a puller with small diameter spindle, also fit thrust plate 30-11 between thrust pad 447 H and puller.
• ◆ With letters CPU, CXF and CXZ, thrust plate 40-105 must be used.
• ◆ There is a slot in the bearing seat in the differential housing for applying puller -A-.

→ Fig.6    Pressing on left taper roller bearing inner race

• ‒ Heat the inner race to approx. 100 oC, position and push to final position.

Note:

With gearbox code letters CPU, CXF and CXZ, thrust sleeve 40-21 must be used.

→ Fig.7    Knocking left taper roller bearing outer race out of cover

• ‒ Turn webs -A- and -B- out until they sit on the outer race within the recess in the gearbox.
• ‒ After removing check shims for damage.

→ Fig.8    Driving left taper roller bearing outer race into cover (gearbox without reinforcements).

• ‒ Thrust piece VW 472/1 is fitted with the taper in the outer race.

Note:

With gearbox code letters CPU, CXF and CXZ, thrust plate VW 511-205 and drift VW 295 must be used.

→ Fig.9    Driving left taper roller bearing outer race into cover (gearbox with reinforcements from 08.98 ä)

Fig.5

• ‒ Press the outer race for the left taper roller bearing into the cover using thrust piece 2050.
• ‒ Thrust piece 2050 is fitted with the taper in the outer race.

→ Fig.10    Driving crown wheel off housing

→ Fig.11    Fitting crown wheel

• ‒ When fitting crown wheel guide it on centring pins -A- (locally made).
• ‒ Heat the crown wheel to approx. 100 oC and position.
• ‒ Allow the crown wheel to cool off slightly before inserting the bolts. Then tighten to the specified torque.

→ Fig.12     Installing small bevel gears

• ‒ Lubricate one-piece thrust washer with gearbox oil and install.
• ‒ Insert large bevel gears.
• ‒ Insert small bevel gears spaced 180o apart, and then rotate into place -arrow-.
• ‒ Drive small bevel gear shaft into final position and secure.

→ Fig.13    Removing and installing spring pin

Removing

• ‒ Spring pin with annular groove: pull out using side-cutting pliers
• ‒ Spring pin without annular groove: knock out from behind using a drift.

Installing

• ‒ Drive in spring pin as far as the stop.