Audi Workshop Service and Repair Manuals

Servicing cover for centre differential, removing and installing centre differential

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Tube -VW 416 B-

t	Tube -VW 421-

t	Guide pin -VW 439-

t	Tube -VW 519-

t	Oil seal extractor lever -VW 681-

t	Press tool -40 - 21-

t	Tube -2040-

t	Thrust piece -3002-

t  -VW 771/15- from multi-purpose tool set -VW 771-

t  -1-Internal puller 23.5…30 mm, e.g. -Kukko21/4- t  -3-Splitter 12...115 mm, e.g. -Kukko17/2-

1 -	Gearbox cover

2 -

Spring

3 -	Front needle bearing

q	Pulling out → Fig.

q	Installation position → Fig.

q	Pressing in → Fig.

4 -	Centre differential

q	Do not dismantle

q	Press out after removing flange shaft (rear) → Fig.

q	Renew if damaged

q	Pressing in → Fig.

5 -	Rear needle bearing

q	Pulling out → Fig.

q	Installation position → Fig.

q	Pressing in → Fig.

6 -	Ball bearing

q	For centre differential

q	Pressing off → Fig.

q	Pressing on → Fig.

7 -

Circlip

8 -

Circlip

q	Remove and install together with flange shaft → Fig.

9 -	Ball bearing

q	For flange shaft (rear)

q	Pressing out → Fig.

q	Pressing in → Fig.

10 -

Cover

q	For centre differential

11 -

Circlip

12 -	Sealing cap

q	Removing → Fig.

13 -

O-ring

q	Always renew

q	Grease when installing

14 -

TORX bolt

q

22 Nm

15 -

Oil seal

q	Pull out with oil seal extractor lever -VW 681-

q	Driving in → Fig.

16 -	Damper weight

17 -

Circlip

18 -

TORX bolt

q

35 Nm

q	Self-locking

q	Always renew

19 -	Flange shaft (rear)

q	Removing and installing → Fig.

Removing sealing cap –  Remove circlip -A-. –  Screw an M8 bolt into thread of sealing cap -B-. –  Pull out sealing cap -B- using bolt.

Removing and installing flange shaft (rear) –  Bend open circlip and pull out flange shaft. –  When inserting flange shaft, fit circlip at the same time. t  The circlip must be seated in the base of the groove.

Pressing out centre differential –  Position thrust piece -3002- directly on centre differential through opening -arrow-.

Pressing ball bearing off centre differential -A-Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing ball bearing onto centre differential –  Press ball bearing on as far as stop.

Pressing out ball bearing for flange shaft (rear) –  Remove circlip before pressing out bearing.

Pressing in ball bearing for flange shaft (rear) –  Fit circlip after pressing in bearing.

Pulling out needle bearing -A-Internal puller 23.5...30 mm, e.g. -Kukko 21/4- –  Both needle bearings in the centre differential are removed with the same puller.

Installation position of front needle bearing t  Dimension -a- = 32.5 mm

Installation position of rear needle bearing t  Dimension -a- = 14 mm

Pressing in needle bearing –  Both needle bearings in the centre differential are pressed in with the same special tool.

Pressing in centre differential

Driving in oil seal –  Lightly oil outer circumference of oil seal. t  Installation position: 2 mm below surface of cover –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.