Audi Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and other items required

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

Special tools, workshop equipment, testers, measuring instruments and other items required

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

Special tools, workshop equipment, testers, measuring instruments and other items required

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

Notes:

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

• Gearbox housing1)
• Shim S2
• ◆ Note thickness
• ◆ Adjustment table
• Outer race for taper roller bearing, small 1)
• ◆ Driving out => Fig.11
• ◆ Driving in => Fig.12

• Spring pin
• ◆ Secures drive gear for oil pump on differential housing
• ◆ Need not be removed to replace drive gear
• ◆ Remove bevel gears and drive out with mandrel
• ◆ Driving in => Fig.6
• Inner race for taper roller bearing, small1)
• ◆ Pulling off => Fig.1
• ◆ Pressing on => Fig. 3
• Large drive gear1)
• ◆ For oil pump
• ◆ Installation position => Fig.5
• Crown wheel1)
• ◆ Paired with drive pinion (pinion set)
• ◆ Use mandrel to drive off => Fig.7
• ◆ Fitting on differential housing=>Fig.8

• Differential housing1)
• Hexagon bolt, 60 Nm + further 45° turn
• ◆ Always replace
• ◆ Exclusive use is to be made of genuine replacement parts
• Inner race for taper roller bearing, large 1)
• ◆ Pulling off => Fig.2
• ◆ Pressing on => Fig. 4
• Drive gear for speedometer
• ◆ Removing and installing => Page 39-4
• ◆ Installation position: Collar -arrow- facing differential; drive pin in differential housing recess
• ◆ Do not tilt

• Outer race for taper roller bearing, large 1)
• ◆ Driving out => Fig.13
• ◆ Driving in => Fig.14
• Shim S1
• ◆ Note thickness
• ◆ Adjustment table => Page 39-57
• Cover for differential1)
• ◆ With O-ring
• ◆ Replace O-ring
• ◆ Lubricate O-ring when fitting
• Shim
• ◆ Re-determining thickness => Fig.10
• Sun wheel
• ◆ Installing => Fig.9
• ◆ Adjusting => Fig.10

• Threaded piece
• Thrust washer
• ◆ Check for cracks and chipping
• Planet pinion
• ◆ Installing => Fig.9
• ◆ Adjusting => Fig.10
• Shaft for bevel gears
• ◆ Drive out with mandrel after removing spring pin
• ◆ Align thrust washers before driving in
• Spring pin
• ◆ Always replace
• ◆ Drive in flush

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

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

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

• ‒ Detach drive gear for speedometer.
• ‒ Position thrust plate 40-105 on differential housing before setting up puller.

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

• ‒ Press home inner race/taper roller bearing on differential housing.

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

• ‒ Press home inner race/taper roller bearing on differential housing.
• ‒ Fit drive gear for speedometer.

→ Fig.5    Installation position of large drive gear for oil pump

• ‒ Shoulder -arrow 1- faces away from differential housing.
• ‒ Recess -arrow 2- points towards opening in housing -arrow 3-.
• ‒ Spring pin -arrow 4- acts as driver for fitting large drive gear =>Fig.6.

→ Fig.6    Driving in spring pin for large drive gear -1-

• ‒ Carefully drive in spring pin as far as dimension -a-, taking care not to damage large drive gear -1-.

• Dimension -a- = 1 mm

→ Fig.7    Driving crown wheel off housing

→ Fig.8    Heating crown wheel to approx. 100 °C and fitting

• ‒ When fitting, guide crown wheel with improvised centring pins -A-.

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

→ Fig.9     Installing bevel gears

• ‒ Apply small quantity of grease to thrust washers for planet pinions and insert.
• ‒ Insert sun wheels with selected shims => Fig.10.
• ‒ Insert planet pinions with 180° offset and swivel in (arrow).
• ‒ Fit threaded pieces.

• Installation position: Shoulder facing sun wheel

• ‒ Align thrust washers so that they coincide with hole.
• ‒ Drive bevel gear shaft into final position and secure.

→ Fig.10    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 sun wheels 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 39-50.

• 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-.

Assign shims by way of Parts List.

Shims available

→ Fig.11    Driving small taper roller bearing outer race out of gearbox housing

→ Fig.12    Driving small taper roller bearing outer race into gearbox housing

→ Fig.13    Driving large taper roller bearing outer race out of cover

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

→ Fig.14    Driving large taper roller bearing outer race into cover