Audi Workshop Service and Repair Manuals

Adjusting differential It is necessary to readjust the differential when the following components have been renewed: t  Gearbox housing t  Clutch housing t  Differential cage or the t  Differential tapered roller bearings   Note Shim S1 for tapered roller bearing outer race was discontinued as of gearbox manufacturing date 04 12 6. Bearing seat for tapered roller bearing outer race has been adapted → Fig..

Special tools and workshop equipment required

t	End measuring plate -VW 385/17-

t	Universal dial gauge bracket -VW 387-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Thrust pad -VW 510-

t	Tube -30 - 14-

t	Tube -2040-

t	Tube -3259-

t	Wheel bearing tube -3345-

t	-1- Kukko internal puller 21/7

t  Thrust plate -30 - 205-

t  Dial gauge -VAS 6080- t  Dial gauge extension, 30 mm

–  Press tapered roller bearing outer race (gear wheel side) with shim S1 (always 1 mm thick) into gearbox housing.   Note The tapered roller bearing inner and outer races are paired. Do not interchange.

–  Press tapered roller bearing outer race (opposite gear wheel side) without shim into clutch housing. –  Install differential in gearbox housing. –  Fit clutch housing in place and tighten 5 bolts to torque → Chapter.

–  Attach dial gauge and set to “0” with a preload of 1 mm. A -  Dial gauge extension, 30 mm –  Preload dial gauge to 1 mm and set to “0”. –  Move differential up and down and read off and note play indicated on dial gauge. (1.50 mm in this example.) Determining thickness of shim S2 The specified bearing preload is achieved by adding a constant value (0.35 mm) to the measured value to obtain the required thickness for S2. Example:

Measured value	1.50 mm
+ Preload (constant value)	0.35 mm
Thickness of shim S2 =	1.85 mm

–  Remove clutch housing and press out tapered roller bearing outer race -A-. B -  Internal puller 46...58 mm, e.g. -Kukko 21/7- Different shim thicknesses make it possible to obtain the exact shim thickness required; if necessary, fit 2 shims. –  Fit shim S2 of the required thickness as determined above (1.85 mm in example). For Part Nos. refer to → Electronic parts catalogue. –  Press tapered roller bearing outer race into clutch housing again. –  Fit clutch housing in place and tighten bolts to torque → Chapter.