Audi Workshop Service and Repair Manuals

Removing and installing differential

t	Multi-purpose tool -VW 771-

t	Socket (27 mm) -3257-

t	Torque wrench -V.A.G 1331-

t	-1-Internal puller -Kukko 21/3-

t	Removing and installing is possible with the gearbox installed.

t	The differential can be removed and installed without removing the selector mechanism, input shaft, pinion shaft or gearbox cover. These components must be removed if the differential needs to be adjusted.

t	Inspect polygon bearings for visible damage.

t	The polygon bearings can only be renewed together with the flange shaft.

t	If the polygon bearings do not run smoothly with the flange shaft removed, this does not necessarily indicate that the bearings are defective. A test for noisy bearings can only be performed with the bearings installed.

t	A spacer ring is fitted between the polygon bearing and the differential sun wheel on flange shafts with 30 mm spline diameter → Fig..

t	Adjustment work is required when renewing the parts marked with 1) → Chapter „Table of adjustments“.

1 -	Gearbox housing 1)

q	Housing manufactured from aluminium or magnesium → Item

q	Aluminium version: must only be fitted to an aluminium gearbox cover

q	Magnesium version: must only be fitted to a magnesium gearbox cover

2 -

Oil seal

q	Renewing → Chapter

3 -

Circlip

q

Renew

q	Removing and installing → Fig.

4 -	Spacer ring

q	Is only fitted on flange shafts with a spline diameter of 30 mm

q	Removing → Fig.

q	Installing → Fig.

5 -	Flange shaft

q	Removing and installing → Chapter

q	Flange shaft assembly → Fig.

6 -	Differential with crown wheel1)

q	Can be removed without removing gearbox

q	Dismantling and assembling → Chapter

7 -	Cover for final drive 1)

q	Aluminium version: must only be fitted to an aluminium gearbox housing

q	Magnesium version: must only be fitted to a magnesium gearbox housing

q	Identification → Fig.

q	For correct version, refer to → Electronic parts catalogue

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

8 -

TORX bolt

q

25 Nm

q	On magnesium version: bright metal, different bolt lengths → Fig.

q	Always renew

q	On aluminium version: black, M8 x 42, without washer

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

Removing and installing circlip –  Clamp flange shaft in vice, using jaw protectors. Use new circlip -A- to press old circlip out of groove in flange shaft.

Removing spacer ring A -  Internal puller 18.5 ... 23.5 mm, e.g. -Kukko 21/3- –  If the spacer ring is tight, pull out using multi-purpose tool -VW 771-.

Installing spacer ring –  Drive new spacer ring in onto stop; do not cant ring when doing this.

Flange shaft assembly 1 -  Flange shaft 2 -  Needle bearing (polygon bearing) 3 -  Spacer ring 4 -  Circlip 5 -  Spacer ring - fitted additionally on shafts with 30 mm spline diameter   Note The needle bearing (polygon bearing) does not turn easily when the flange shaft is removed. This does not indicate that the bearing is defective.

Identification of final drive cover On magnesium gearboxes “Mg Al 9 Zn 1” can be found in the area indicated by the arrow. Mg = Magnesium; additional data is only for production.

Locations of bolts for final drive cover on gearboxes with magnesium housing 1 -  Bright metal bolts, M8 x 42, without washer 2 -  Bright metal bolts, M8 x 45, with captive washer –  All bolts in this area must be fitted with a washer.   Note Only M8 x 45 bolts with captive washers are supplied as replacement parts. If required, these must be used for all securing bolts on the final drive cover.