Audi Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Tube -VW 418 A-

t	Thrust plate -30 - 205-

t	Installing sleeve -VW 455-

t	Spacer sleeve -VW 472/2-

t	Press tool -40 - 21-

t	Tube -30 - 14-

t	Tube -2040-

t	Thrust piece -3002-

t	Counterhold tool -3067-

t	Tube -3259-

t	Adapter -V.A.G 1582/3-

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

t	Internal puller -1 - Kukko 21/7-

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

Pulling tapered 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-

Pressing tapered roller bearing outer race into gearbox housing –  Support gearbox housing with tube -3259- directly below bearing mounting.

Pulling off tapered roller bearing inner race   Note The removal procedure is the same for both tapered roller bearing inner races.

Pressing on tapered roller bearing inner race –  Support opposite side of inner race using installing sleeve -VW 455-. Shoulder of installing sleeve -VW 455- points to differential cage.   Note The installation procedure is the same for both tapered roller bearing inner races.

Pressing tapered roller bearing outer race -A- out of clutch housing B -  Internal puller 46 ... 58 mm, e.g. -Kukko 21/7- –  Clamp internal puller firmly under tapered roller bearing outer race.

Pressing tapered roller bearing outer race into clutch housing

Pressing out differential pinion pin The spring pin is sheared off when pressing out. –  Drive the remaining part of the spring pin out of the 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). –  Insert 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. –  Drive differential pinion pin into final position and secure with spring pin.