Audi Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Gearbox with stub shaft (right-side): press tool -VW 473-

t	Thrust plate -40 - 105-

t	Thrust plate -3005-

t  Gearbox with flange shaft (right-side): tube -VW 415 A-

t	Tube -3259-

t	Tube -3296-

t	Wheel bearing tube -3345-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/6A-

t	-1-Internal puller 46 ... 58 mm -Kukko 21/7-

t	-2-Puller -Kukko 18/1-

t	-3-Splitter 12 ... 75 mm -Kukko 17/1-

t	-4-Counter-support -Kukko 22/2-

Pulling tapered roller bearing outer race out of clutch housing A -  Counter-support -Kukko 22/2- B -  Internal puller 46 ... 58 mm -Kukko 21/7-   Note After pulling out, check shim for damage and renew if necessary.

Pressing tapered roller bearing outer race into clutch housing –  First install shim. l  Installation position of shim: Shoulder on inside diameter faces towards oil seal

Pulling off tapered roller bearing inner race –  Before applying puller, place thrust plate -40 - 105- on differential cage.

Pressing on tapered roller bearing inner race   WARNING Wear protective gloves. –  Heat tapered roller bearing inner race to approx. 100°C before pressing on.

Pulling off tapered roller bearing inner race A -  Puller -Kukko 18/1- B -  Splitter 12 ... 75 mm -Kukko 17/1-

Gearbox with stub shaft (right-side): Pressing on tapered roller bearing inner race –  Place smaller diameter of press tool -VW 473- on tapered roller bearing inner race. l  Cage with bearing rollers must rotate freely when pressing on.

Gearbox with flange shaft (right-side): Pressing on tapered roller bearing inner race l  Cage with bearing rollers must rotate freely when pressing on.

Pulling tapered roller bearing outer race out of gearbox housing A -  Counter-support -Kukko 22/2- B -  Internal puller 46 ... 58 mm -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Place tube for wheel bearing -3345- directly under bearing mounting to support gearbox housing.

Removing and installing spring pin for differential pinion pin Removing: –  Cover tapered roller bearing inner race to avoid damage and keep metal particles out of the bearing. –  Drive out spring pin with chisel, inserting chisel into annular groove. Installing: –  Drive spring pin onto stop in differential cage.

Installing bevel gears –  Lubricate one-piece thrust washer with gear oil and install. –  Install both sun wheels and secure (e.g. with flange shaft). –  Fit planet pinions (180° apart) and pivot into position. –  Push differential pinion pin -arrow A- in as far as first planet pinion. –  Fit threaded pieces -arrows B- in sun wheels. l  Installation position: Stepped shoulder towards sun wheel –  Drive differential pinion pin into final position and secure with spring pin.