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 407-

t	Press tool -VW 408 A-

t	Thrust plate -VW 447 H-

t	Thrust plate -VW 447 i-

t	Press tool -VW 472/1-

t	Thrust piece -2050-

t	Drift -3138-

t	Sleeve -3144-

t	Tube -3296-

t	Torque wrench -V.A.G 1332-

t	Removal and installing tool -VW 459-

t	-1-Internal puller -Kukko 21/7-

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

t	-3-Puller -Kukko 204/2-

t	Two-arm puller -Kukko 44/2-

t	Removing and installing differential → Chapter

t	Always renew both tapered roller bearings together.

t	Adjustment work is required when renewing the parts marked with 1) → Chapter.

1 -	Gearbox housing 1)

2 -

Shim “S2”

q	Note thickness

q	Table of adjustments → Chapter

3 -	Outer race for tapered roller bearing (right-side) 1)

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Inner race for tapered roller bearing (right-side) 1)

q	Pulling off → Fig.

q	Pressing on → Fig.

5 -	Crown wheel1)

q	Is paired with pinion shaft (final drive gear set)

q	Select correct version according to gearbox code letters → Electronic parts catalogue → Chapter

q	Drive crown wheel off differential cage using a punch → Fig.

q	Fitting on differential cage → Fig.

6 -	Differential cage1)

q	Select correct version according to gearbox code letters → Electronic parts catalogue → Chapter

7 -

Bolt

q	60 Nm and turn 45° further

q	Always renew

q	Lightly tighten bolts then tighten in diagonal sequence to correct torque

8 -	Inner race for tapered roller bearing (left-side) 1)

q	Pulling off → Fig.

q	Pressing on → Fig.

q	For correct version, refer to → Electronic parts catalogue

9 -	Speedometer drive wheel

q	Removing and installing → Chapter

q	Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use force; the drive wheel can break easily.

q	Not fitted from 07.02 onwards

10 -	Outer race for tapered roller bearing (left-side) 1)

q	Driving out → Fig.

q	Pressing in → Fig.

q	For correct version, refer to → Electronic parts catalogue

11 -

Shim “S1”

q	Note thickness

q	Table of adjustments → Chapter

q	For correct version, refer to → Electronic parts catalogue

12 -	Cover for final drive 1)

q	Coat sealing surfaces lightly with sealing paste -AMV 188 001 02-

q	For correct version, refer to → Electronic parts catalogue

13 -

Sun wheel

q	Installing → Fig.

14 -	Differential pinion pin

q	Drive out with drift after removing spring pin

15 -	Spring pin

q	Secures differential pinion pin

q	Version with annular groove: removing and installing → Fig.

q	Version without annular groove: knock out with drift

16 -	Planet pinion

q	Installing → Fig.

17 -	One-piece thrust washer

q	Lubricate with gear oil before installing

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 46...58 mm, e.g. -Kukko 21/7- –  After removing, check shims for damage.

Pressing outer race for tapered roller bearing into gearbox housing –  The taper of press tool -VW 472/1- is applied in the outer race. –  Support gearbox housing with -VW 459/2- directly below bearing mounting.

Pulling off inner race for tapered roller bearing (right-side) A -  Two-arm puller, e.g. -Kukko 44/2- or -Kukko 20/10-   Note There is a slot under the bearing seat in the differential cage for applying puller -A-.

Pressing on inner race for tapered roller bearing (right-side)   WARNING Wear protective gloves. –  Heat inner race to approx. 100 °C, fit in position and press home.

Pulling off inner race for tapered roller bearing (left-side) A -  Two-arm puller, e.g. -Kukko 204/2-   Note There is a slot under the bearing seat in the differential cage for applying puller -A-.

Fitting inner race for tapered roller bearing (left-side)   WARNING Wear protective gloves. –  Heat inner race to approx. 100 °C, fit in position and press home.

Knocking outer race for tapered roller bearing (left-side) out of cover –  Turn the lugs -A- and -B- out until they bear against the outer race within the recess in the housing. –  After removing, check shims for damage.

Driving outer race for tapered roller bearing (left-side) into cover –  Press outer race for tapered roller bearing (left-side) into cover using thrust piece -2050-. –  The taper of thrust piece -2050- is applied in the outer race.

Driving crown wheel off cage

Heating crown wheel to approx. 100 °C and installing   WARNING Wear protective gloves. –  When fitting crown wheel, use centralising pins -A- (shop-made tool) to locate. –  Allow to cool slightly before screwing in bolts. Then tighten all bolts in diagonal sequence to specified torque.

Installing differential bevel gears –  Lubricate one-piece thrust washer with gear oil and install. –  Install sun wheels. –  Insert planet pinions (180° apart) and pivot into position -arrow-. –  Drive differential pinion pin into final position and secure.

Removing and installing spring pin Removing –  Spring pin with annular groove: pull out using side-cutting pliers. –  Spring pin without annular groove: knock out from behind using a punch. Installing –  Drive in spring pin as far as the stop.