Audi Workshop Service and Repair Manuals

Special tools, testers and other items required

• ‒ Thrust plate VW 401
• ‒ Thrust plate VW 402
• ‒ Press tool VW 407
• ‒ Press tool VW 412
• ‒ Mandrel VW 295
• ‒ Press tool VW 408 A

• ‒ Thrust pad VW 442
• ‒ Fitting sleeve 40-21
• ‒ Thrust plate 40-105
• ‒ Thrust pad 2050
• ‒ Driving-out tool 3138
• ‒ Two-arm puller, Kukko 44/2

• ◆ Taper roller bearing puller V.A.G 1582

• ◆ Gripper V.A.G 1582/6

Notes:

• ◆ General repair instructions .
• ◆ Always replace both differential taper roller bearings jointly. Use same makes wherever possible.
• ◆ Replacement of components marked 1) necessitates adjustment work => Adjustment table, Page 39-176.

• Cover for final drive 1)
• O-ring
• ◆ Replace
• ◆ Oil on insertion
• Final drive housing 1)

• Shim "S2"
• ◆ Note thickness
• ◆ Adjustment table
• Outer race for taper roller bearing, small 1)
• ◆ Driving out => Fig.1
• ◆ Pressing in => Fig.2
• Inner race for taper roller bearing, small 1)
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig. 4
• Bolt, 60 Nm + further 45°turn
• ◆ Replace
• ◆ Assignment

=> Parts List

• ◆ Tighten bolts alternately and then diagonally to torque

• Differential housing 1)
• Crown wheel 1)
• ◆ Paired with drive pinion (pinion set)
• ◆ Assignment in line with gearbox code letters

=> Parts List

• ◆ Driving off housing with mandrel
  => Fig.9
• ◆ Fitting on differential housing
  => Fig.10

• Spring pin
• ◆ For securing bevel gear shaft
• ◆ Drive in flush
• Inner race for taper roller bearing, large 1)
• ◆ Pulling off => Fig.5
• ◆ Pressing on => Fig. 6

• Outer race for taper roller bearing, large 1)
• ◆ Driving out => Fig.7
• ◆ Pressing in => Fig.8
• Shim "S1"
• ◆ Note thickness
• ◆ Adjustment table=> Page 39-176
• Threaded piece
• Sun wheel
• ◆ Installing => Fig.11
• ◆ Adjusting => Fig.12
• Planet pinion
• ◆ Installing => Fig.11

• Shaft for bevel gears
• ◆ Drive out with mandrel
• ◆ Drive in carefully, so as not to damage thrust washers
• ◆ Secure with spring pin -Item 10-
• Shim
• ◆ Re-determining thickness => Fig.12
• Thrust washer
• ◆ Check for cracks

→ Fig.1    Driving outer race for taper roller bearing, small out of housing

• ‒ Check shims for damage following removal.

→ Fig.2    Pressing home outer race for taper roller bearing, small in housing

• ‒ Fit outer race evenly in position with VW 295 by tapping gently with hammer.
• ‒ Then drive home as shown.

→ Fig.3    Pulling off inner race for taper roller bearing, small

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

→ Fig.4    Pressing on inner race for taper roller bearing, small

• ‒ Heat inner race to approx. 100 °C, place in position and press home.

→ Fig.5    Pulling off inner race for taper roller bearing, large

• ‒ Position thrust plate 40-105 on differential housing before setting up puller.

→ Fig.6    Pressing on inner race for taper roller bearing, large

• ‒ Heat inner race to approx. 100 °C, place in position and press home.

→ Fig.7    Driving outer race for taper roller bearing, large out of cover

• ‒ Check shims for damage following removal.

→ Fig.8    Pressing outer race for taper roller bearing, large into cover

→ Fig.9    Driving crown wheel off housing

→ Fig.10    Fitting crown wheel

• ‒ When fitting, guide crown wheel with improvised centring pins -A-.
• ‒ Heat crown wheel to approx. 100 °C and fit in position.

→ Fig.11     Installing bevel gears

• ‒ If sun wheels are replaced, shims must be re-determined => Fig.12.
• ‒ Fit sun wheels with shims determined.
• ‒ Insert planet pinions with 180° offset and swivel in -arrow-.
• ‒ Insert and align thrust washers.
• ‒ Insert threaded pieces.
• ‒ Drive bevel gear shaft into final position and secure.

→ Fig.12    Adjusting bevel gears

• ‒ Insert sun wheels with thinnest shims (0.5 mm).
• ‒ Insert planet pinions with 180° offset with thrust washers.

Note:

From now on bevel gears and thrust washers are not to be interchanged.

• ‒ Drive in shaft for bevel gears.
• ‒ Press planet pinions outwards.
• ‒ Press sun wheels in direction of arrow and check clearance.
• ‒ Determine thickest shim which can still just be fitted for sun wheels on either side.
• ‒ Shims for both sides should be of same thickness
• ‒ Determine shims as per table. Part numbers

=> Parts List

Shims available:

Note:

→ Correct setting has also been made if there is no perceptible clearance, but bevel gears can still just be turned -arrow-.