Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 353 Gearbox support
• ◆ VW 401 Thrust plate
• ◆ VW 402 Thrust plate
• ◆ VW 407 Press tool
• ◆ VW 408 A Press tool
• ◆ VW 412 Press tool

Special tools and workshop equipment required

• ◆ 40-105 Thrust plate
• ◆ 3005 Press disk
• ◆ 3259 Tube
• ◆ 3296 Tube
• ◆ 3345 Tube
• ◆ V.A.G 1332 Torque wrench

Special tools and workshop equipment required

• ◆ V.A.G 1582 Taper roller bearing puller
• ◆ V.A.G 1582/6 Grip
• ◆ 1 - Kukko 21/7 Internal puller
• ◆ 4 - Kukko 22/2 Counter support

Notes:

• ◆ Heat taper roller bearing inner race to
  100 °C before installing.
• ◆ Always renew both taper roller bearings together as a set.
• ◆ If taper roller bearings, differential housing, gearbox housing or clutch housing are renewed, adjust differential .

• Gearbox housing
• Bolt
• Differential cage
• ◆ Bolt to final drive gear

• Final drive gear wheel
• ◆ Rivetted in production
• ◆ Pressing off => Fig.8
• ◆ Fitting position: machined side faces towards bolting surface of differential housing.
• ◆ Heat to 100 °C before installing
• ◆ Fit to differential housing
  => Fig.9
• ◆ Bolted => Fig.10
• Backing plate
• Nut, 40 Nm and turn 45° further
• Clutch housing
• Shim
• ◆ For differential
• ◆ Determining thickness => Page 39-24

• Taper roller bearing outer race
• ◆ Pulling out => Fig.5
• ◆ Pressing in => Fig.6
• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig.4
• Differential housing
• ◆ With rivetted final drive gear
• ◆ When renewing final drive gear drill out rivet heads => Fig.7
• ◆ Attaching final drive gear with bolts
  => Fig.10
• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig.4
• Taper roller bearing outer race
• ◆ Pulling out => Fig.1
• ◆ Pressing in => Fig.2

• Shim
• ◆ Always 0.65 mm thick
• Oil seal
• ◆ For right-hand flange shaft
• ◆ Left and right-hand diameters differ.
• ◆ Renewing with gearbox installed => Page 39-1
• Cone head bolt, 25 Nm
• ◆ Bolt into threaded piece (item26)
• Left-hand flange shaft
• ◆ Do not interchange, left and right-hand flange shafts differ
• Spring for flange shaft
• ◆ Installed behind flange shafts

• Thrust washer
• ◆ Installation position:
  Shoulder towards spring, tongue to tapered ring
• Tapered ring
• ◆ With grooves to secure thrust washer
• ◆ Installation position: Taper towards differential housing
• Securing clip
• ◆ Ensures that taper ring, thrust washer and spring are held in position when flange shaft is removed
• Sun wheel
• ◆ Installing => Fig. 12
• Planet pinion axis shaft
• ◆ Knock out with drift
• ◆ Installing => Fig. 12

• Spring pin
• ◆ For securing planet pinion axis shaft
• ◆ Removing and installing => Fig. 11
• Planet pinion
• ◆ Installing => Fig. 12
• Threaded piece
• ◆ Installing => Fig. 12
• One-piece thrust washer
• ◆ Coat with gearbox oil when installing
• Left-hand flange shaft
• ◆ Do not interchange, left and right-hand flange shafts differ
• Oil seal
• ◆ For left-hand flange shaft
• ◆ Left and right-hand diameters differ.
• ◆ Renewing with gearbox installed => Page 39-1

→ Fig.1    Pulling taper roller bearing outer race out of clutch housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

Note:

After pressing out, check washer for damage and renew if necessary.

→ Fig.2    Pressing taper roller bearing outer race into clutch housing

• ‒ First insert washer.

→ Fig.3    Pulling off taper roller bearing inner race

• ‒ Before fitting the extractor position press piece 40-105 on differential housing.

Note:

Both both taper roller bearing inner races are pulled off the differential housing in the same way.

→ Fig.4    Pressing on taper roller bearing inner race

Note:

The taper roller bearing inner races for gearbox housing and clutch housing are pressed on with the same press tools.

→ Fig.5    Pulling taper roller bearing outer race out of gearbox housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 46...58 mm, e.g. Kukko 21/7

→ Fig.6    Pressing taper roller bearing outer race into gearbox housing

• ‒ Support gearbox housing with tube 3345 directly below bearing mounting.

→ Fig.7    Drilling out rivet heads

• ‒ Drill out rivet heads with 12 mm drill from countersunk side
  and drive rivet out with drift.

Note:

Clean differential before and after drilling, protect taper roller bearing from drillings.

→ Fig.8    Pressing off final drive gear

• ‒ Place thrust piece 40-105 on differential housing.

→ Fig.9    Heating final drive gear wheel to approx. 100 °C and installing

• ‒ Use bolts -A- from repair kit to guide final drive gear into position during installation.

→ Fig.10     Bolting final drive gear -A- and differential housing -B- together

Use special bolts -1- with backing plates -2- and nuts -3- according to parts catalogue.

→ Fig.11    Removing and installing planet pinion axis shaft spring pin

Removing

• ‒ Cover taper roller bearing inner race to avoid possible damage and ingress of metal particles.
• ‒ Knock-out spring pin with chisel, inserting chisel into circumferential groove.

Installing

• ‒ Knock fully into the differential cage.

→ Fig.12     Installing sun wheels and planet pinions

• ‒ Lubricate one piece thrust washer with gearbox oil and install.
• ‒ Install both sun wheels and secure (e.g. with flange shaft).
• ‒ Insert planet wheels (180°apart) and pivot into position.
• ‒ Push planet wheel axis shaft (arrow -A-) in until first planet wheel.
• ‒ Position threaded pieces (arrow -B-) in sun wheels
  Installation position: step towards sun wheel
• ‒ Drive planet wheel axis shaft into final position and secure with spring pin.