Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Thrust plate VW 401
• ◆ Thrust plate VW 402
• ◆ Press tool VW 412
• ◆ Tubular section VW 415 A
• ◆ Spacer sleeve VW 472/2
• ◆ Support ring 2006 A

• ◆ 1 - Internal puller Kukko 21/6
  and internal puller Kukko 21/7
• ◆ 4 - Counter-support Kukko 22/2

• End cover
• ◆ If replaced:
• ‒ Re-determine thickness of circlip
  -Item 5-
• ‒ Re-determine shims for Torsen differential
• Oil drain plug, 40 Nm
• Cylindrical roller bearing for input shaft
• ◆ Extracting => Fig.1
• ◆ Pressing in flush => Fig.2
• Ball bearing for input shaft
• ◆ Removing => Fig.3
• ◆ Installing => Fig.4
• ◆ On replacement, re-determine thickness of circlip -Item 5-

• Circlip
• ◆ Re-determining thickness
  => Page 34-228
• ◆ Installing => Fig.4
• Baffle plate
• ◆ Replace
• ◆ Removing => Fig.3
• ◆ Installing and peening on replacing ball bearing for input shaft => Fig.5
• ◆ Installing and peening on replacing end cover => Fig.6
• Torsen differential needle bearing
• ◆ Extracting => Fig.7
• ◆ Driving in => Fig.8

→ Fig.1    Extracting cylindrical roller bearing for input shaft from end cover

•     A -    Internal puller 37 ... 46 mm, e.g. Kukko 21/6
•     B -    Spindle from counter-support Kukko 22/2

→ Fig.2    Pressing cylindrical roller bearing for input shaft into end cover so as to be flush

• ◆ Shoulder of tubular section VW 415 a faces press tool VW 412

→ Fig.3    Removing ball bearing for input shaft from end cover

• ‒ Apply screwdriver as shown, knock into baffle plate -arrow- and prise out.
• ‒ Remove circlip.
• ‒ Take out bearing and eliminate peening depressions if necessary.

→ Fig.4    Installing ball bearing for input shaft in end cover

Installation position of circlip:

• ◆ Ends of circlip -arrows- face needle bearing

Note:

Circlip thickness must be re-determined on replacing bearing or end cover.

• ‒ Determining circlip for ball bearing for input shaft:
• ‒ Press home outer race of ball bearing.
• ‒ Determine thickest circlip which can still just be fitted.
• ‒ Axial clearance: max. 0.08 mm
• ‒ Determine circlip from table. Part numbers

=> Parts List

Circlips available:

• ‒ Fit circlip.

→ Fig.5    Peening baffle plate on replacing ball bearing for input shaft

• ‒ For peening, make use of blunt centre punch with spherical end (ball ø 5 mm).
• ‒ Insert baffle plate.
• ‒ Perform initial peening -arrows 1-.
• ‒ Perform second peening operation -arrows 2- at a distance -a- from initial peening operation.
• ‒ Dimension a = 5 mm
• ‒ Observe position and ø of peening points:
• ‒ Dimension b = 2 mm
• ‒ Dimension c = 3 mm

→ Fig.6    Peening baffle plate on replacing end cover

• ‒ For peening, make use of blunt centre punch with spherical end (ball ø 5 mm).
• ‒ Insert baffle plate.
• ‒ Set first peening point -arrow- at a distance -d- from connecting line of shaft centres.
• ‒ Dimension d = 10 mm
• ‒ Observe position and ø of peening points:
• ‒ Dimension b = 2 mm
• ‒ Dimension c = 3 mm
• ‒ Set second and third peening points in the same manner at distance -a-.
• ‒ Dimension a = 70 mm

→ Fig.7    Extracting needle bearing for Torsen differential out of end cover

•     A -    Internal puller 46 ... 58 mm, e.g. Kukko 21/7
•     B -    Spindle from counter-support Kukko 22/2

→ Fig.8    Driving needle bearing for Torsen differential flush into end cover

• ‒ Place press tool VW 412 with shoulder facing upwards on bearing.