Audi Workshop Service and Repair Manuals

Dismantling and assembling differential

Special tools and workshop equipment required

t	Drift -VW 295-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Removal and installing tool -VW 459-

t	Thrust pieces for pinion shaft bearing -VW 470-

t	Thrust plate -30-205-

t	Mandrel -30-505-

t	Press tool -40-21-

t	Thrust plate -40-105-

t	Thrust pad -3062-

t	Drift -3138-

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

t	Adapter -V.A.G 1582/3-

t	Adapter -V.A.G 1582/6-

Differential - exploded view of components

Adjustment is required if gearbox housing, differential cage, cover for final drive, crown wheel or tapered roller bearings are being renewed → Anchor.

1 -	Gearbox housing

2 -

Shim “S2”

q	Note thickness

q	Table of adjustments → Anchor

3 -	Small tapered roller bearing outer race

q	Driving out → Fig.

q	Driving in → Fig.

4 -	Small tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

q	Low-friction bearing; do not oil bearing when measuring friction torque

5 -	Crown wheel

q	Is mated with pinion shaft (final drive gear set), always renew together as a set

q	Select correct version according to code letters → Parts catalogue

q	Removing → Fig.

q	Installing → Fig.

6 -	Differential cage

7 -	Crown wheel bolt, 60 Nm + 45° further

q

Renew

q	Use only genuine bolts

8 -	Large tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

q	Low-friction bearing; do not oil bearing when measuring friction torque

9 -	Drive wheel

q	For speedometer sender -G22-

q	Not fitted from 07.2002

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	Installation position: shoulder -arrow- towards differential

10 -	Large tapered roller bearing outer race

q	Driving out → Fig.

q	Driving in → Fig.

11 -

Shim “S1”

q	Note thickness

q	Table of adjustments → Anchor

12 -	Cover for final drive

q	With O-ring

q	Renew O-ring

q	Lubricate O-ring with oil before installing

13 -

Shims

q	Re-determining thickness → Fig.

14 -	Sun wheels

q	Installing → Fig.

q	Adjusting → Fig.

15 -	Threaded piece

16 -	Thrust washer

q	Check for cracks and chipping

17 -	Planet pinions

q	Installing → Fig.

q	Adjusting → Fig.

18 -	Differential pinion pin

q	Drive out with drift after removing spring pin

q	Align thrust washers before driving in

19 -	Spring pin

q

Renew

q	Drive in flush

Pulling inner race for small tapered roller bearing off differential cage –  Position thrust plate -40-105- before applying puller.

Pulling inner race for large tapered roller bearing off differential cage –  If fitted, remove drive wheel for speedometer sender -G22-. –  Position thrust plate -40-105- before applying puller.

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

Pressing on inner race for large tapered roller bearing –  Heat inner race to approx. 100 °C, fit in position and press home.   WARNING Wear protective gloves. –  If fitted, position drive wheel for speedometer sender -G22-.

Driving crown wheel off differential cage

Installing crown wheel –  Use 2 centring pins -A- (local manufacture) as a guide. –  Heat crown wheel to approx. 100 °C and install.   WARNING Wear protective gloves. –  Allow to cool slightly before screwing in bolts. Then tighten to specified torque.

Installing differential bevel gears –  If fitted, carefully lever off drive wheel for speedometer sender -G22- using screwdriver. –  Apply a small quantity of grease to thrust washers for planet pinions and install thrust washers. –  Insert sun wheels with selected shims → Fig.. –  Insert planet pinions offset 180° and rotate into position -arrow-. –  Insert threaded pieces. l  Installation position: stepped shoulder towards sun wheel. –  Locate thrust washers and planet pinions so that they align with the holes. –  Drive differential pinion pin into final position and secure.

Adjusting differential bevel gears –  Insert sun wheels with thinnest shims (0.5 mm). –  Insert planet pinions with thrust washers and press in shaft.   Note Ensure that bevel gears and thrust washers are not interchanged from this point onwards. –  Press planet pinions outwards and check clearance of sun wheels by hand -arrows-. –  Adjust clearance by inserting an appropriate shim → Anchor. l  Specification: max. 0.10 mm.   Note

The adjustment is also correct if no further play is perceptible, although it is still just possible to rotate the differential bevel gears -arrow-. –  Select required shim thickness from following table:

Available shims - Thickness of shims in mm 1)
0.50	0.70	0.90
0.60	0.80	1.00
l  1) Part numbers → Parts catalogue.

Driving outer race for small tapered roller bearing out of gearbox housing

Driving outer race for small tapered roller bearing into gearbox housing

Driving outer race for large tapered roller bearing out of cover –  Use a suitable base, e.g. thrust pieces for drive pinion bearing -VW 470- with recess towards cover.

Driving outer race for large tapered roller bearing into cover