Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Mandrel VW 295
• ◆ Thrust plate VW 401
• ◆ Thrust plate VW 402
• ◆ Press tool VW 412
• ◆ Pressing-out and pressing-in tool VW 459
• ◆ Pressing-off tool for drive pinion bearing VW 470

• ◆ Thrust plate 30-205
• ◆ Fitting mandrel 30-505
• ◆ Fitting sleeve 40-21
• ◆ Thrust plate 40-105
• ◆ Thrust pad 3062
• ◆ Driving-out tool 3138

• ◆ Taper roller bearing puller V.A.G 1582
• ◆ Gripper V.A.G 1582/3
• ◆ Gripper V.A.G 1582/6

Notes:

• ◆ Removing and installing differential
  
• ◆ Replacement of components marked 1) necessitates adjustment work => Adjustment table, Page 39-57.

• Gearbox housing 1)
• Shim "S2"
• ◆ Note thickness
• ◆ Adjustment table
• Outer race for taper roller bearing, small 1)
• ◆ Driving out => Fig.9
• ◆ Driving in => Fig.10
• Inner race for taper roller bearing, small 1)
• ◆ Pulling off => Fig.1
• ◆ Pressing on => Fig. 3
• ◆ Low-friction bearing; do not lubricate for friction torque measurement

• Crown wheel 1)
• ◆ Paired with drive pinion (pinion set)
• ◆ Removing => Fig.5
• ◆ Installing => Fig.6
• Differential housing 1)
• Hexagon bolt, 60 Nm + further 45° turn
• ◆ Always replace
• ◆ Exclusive use is to be made of genuine bolts
• Inner race for taper roller bearing, large 1)
• ◆ Pulling off => Fig.2
• ◆ Pressing on => Fig. 4
• ◆ Low-friction bearing; do not lubricate for friction torque measurement

• Drive wheel
• ◆ For speedometer sender
• ◆ Removing and installing => Page 39-4
• ◆ Attach carefully to differential, taking care not to tilt; do not use force as this could break drive wheel
• ◆ Installation position: Web -arrow- facing differential
• Outer race for taper roller bearing, large 1)
• ◆ Driving out => Fig.11
• ◆ Driving in => Fig.12
• Shim "S1"
• ◆ Note thickness
• ◆ Adjustment table => Page 39-57
• Cover for differential1)
• ◆ With O-ring
• ◆ Replace O-ring
• ◆ Lubricate O-ring when fitting

• Shims
• ◆ Re-determining thickness => Fig.8
• Sun wheels
• ◆ Adjusting => Fig.8
• Threaded piece
• Thrust washer
• ◆ Check for cracks and chipping
• Planet pinions
• ◆ Installing => Fig.7
• Shaft for bevel gears
• ◆ Drive out with mandrel after removing spring pin
• ◆ Align thrust washers before driving in
• Spring pin
• ◆ Replace
• ◆ Drive in flush

→ Fig.1    Pulling inner race for taper roller bearing, small off housing

• ‒ Fit thrust plate 40-105 before positioning puller.

→ Fig.2    Pulling inner race for taper roller bearing, large off housing

• ‒ Detach drive gear for speedometer.
• ‒ Fit thrust plate 40-105 before positioning puller.

→ Fig.3    Pressing on inner race for taper roller bearing, small

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

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

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

→ Fig.5    Driving crown wheel off housing

→ Fig.6    Fitting crown wheel

• ‒ Use 2 improvised centring pins -A- as a guide.
• ‒ Heat crown wheel to approx. 100 °C and fit in position.

• ‒ Allow to cool slightly before screwing in bolts. Then tighten to torque.

→ Fig.7    Installing bevel gears

• ‒ Use screwdriver to carefully prise off drive wheel for speedometer sender.
• ‒ Apply small quantity of grease to thrust washers for planet pinions and insert.
• ‒ Insert sun wheels with selected shims => Fig.8.
• ‒ Insert planet pinions with 180° offset and swivel in -arrow-.
• ‒ Fit threaded pieces.
• ‒ Installation position: Shoulder facing sun wheel
• ‒ Align thrust washers and bevel gears so that they coincide with hole.
• ‒ Drive bevel gear shaft into final position and secure.

→ Fig.8    Adjusting bevel gears

• ‒ Insert sun wheels with thinnest shims (0.5 mm).
• ‒ Insert planet pinions with thrust washers and press in shaft.

Note:

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

• ‒ Press planet pinions outwards and check clearance of sun wheels by hand -arrows-.
• ‒ Adjust clearance by inserting appropriate shim => Page 39-31.
• ‒ Specification: max. 0.10 mm

Note:

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

• ‒ Determine shim as per table. Part numbers

=> Parts List

Shims available

→ Fig.9    Driving outer race for taper roller bearing, small out of gearbox housing

Fig.10    → Driving outer race for taper roller bearing, small into gearbox housing

→ Fig.11    Driving outer race for taper roller bearing, large out of cover

• ‒ Use suitable support, e.g. VW 470 with recess facing cover.

→ Fig.12    Driving outer race for taper roller bearing, large into cover