Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary equipment required

• ◆ Thrust plates VW 401 and VW 402
• ◆ Press tool VW 407
• ◆ Press tool VW 412
• ◆ Tube VW 416 B
• ◆ Tube VW 421
• ◆ Guide piece VW 439
• ◆ Tube VW 519
• ◆ Extractor lever VW 681
• ◆ VW 771/15 from multi-purpose tool set VW 771
• ◆ Sleeve 40-21
• ◆ Tube 2040
• ◆ Thrust piece 3002
• ◆ Separating tool Kukko 17/2
• ◆ Internal puller Kukko 21/4

• Gearbox cover
• Spring
• Front needle roller bearing
• ◆ Pulling out =>Fig.8
• ◆ Installation position => Fig.9
• ◆ Pressing in => Fig.11
• Torsen differential
• ◆ Do not dismantle
• ◆ Press out after removing flange shaft => Fig.3
• ◆ Replace, if damaged
• ◆ Pressing in => Fig.12
• Rear needle roller bearing
• ◆ Pulling out =>Fig.8
• ◆ Installation position => Fig.10
• ◆ Pressing in => Fig.11

• Ball bearing
• ◆ For Torsen differential
• ◆ Pressing off => Fig.4
• ◆ Pressing on =>Fig.5
• Circlip
• Circlip
• ◆ Remove and install together with flange shaft => Fig.2
• Ball bearing
• ◆ For flange shaft
• ◆ Pressing out =>Fig.6
• ◆ Pressing in => Fig.7
• Cap
• ◆ For Torsen differential
• Circlip
• Cap
• ◆ Removing =>Fig.1

• O-ring
• ◆ Replace
• ◆ Grease when installing
• TORX-screw - 22 Nm
• Sealing ring
• ◆ Pull out with lever VW 681
• ◆ Tapping in =>Fig.13
• Vibration damper
• Circlip
• TORX-screw - 35 Nm
• ◆ Self-locking
• ◆ Replace
• Flange shaft
• ◆ Removing and installing => Fig.2

→ Fig.1    Removing sealing cap

• ‒ Remove circlip -A-.
• ‒ Screw M8 bolt into thread of sealing cap -B-.
• ‒ Pull out sealing cap -8- using bolt.

→ Fig.2    Removing and installing flange shaft

• ‒ Open out circlip and pull out flange shaft.
• ‒ When inserting flange shaft, fit circlip at the same time.
• ‒ Circlip must be properly seated in the base of the groove

→ Fig.3    Pressing out Torsen differential

• ‒ Position thrust piece 3002 directly on Torsen differential through opening (arrow).

→ Fig.4    Pressing off ball bearing from Torsen differential

•     A -    Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.5    Pressing ball bearing onto Torsen differential

• ‒ Press the ball bearing on as far as stop.

→ Fig.6    Pressing out ball bearing for flange shaft

• ‒ Remove circlip before pressing off.

→ Fig.7    Pressing in ball bearing for flange shaft

• ‒ Fit circlip after pressing in bearing.

→ Fig.8    Pulling out needle roller bearing

•     A -    Internal puller 22 ... 28 mm, e.g. Kukko 21/4

• ‒ Both needle roller bearings in Torsen differential are removed with same puller.

→ Fig.9    Installation position of front needle roller bearing

• ◆ Distance a = 32.5 mm

→ Fig.10    Installation position of rear needle roller bearing

• ◆ Distance a = 14 mm

→ Fig.11    Pressing in needle roller bearing

• ‒ Both needle roller bearings in Torsen differential are pressed in with same special tool.

→ Fig.12    Pressing in Torsen differential

→ Fig.13    Inserting oil seal

• ‒ Fill space between sealing and dust lips with multipurpose grease.
• ‒ Lightly oil outer circumference of seal.
• ‒ Installation position: 2 mm below surface of cover