Audi Workshop Service and Repair Manuals

Exploded view - 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	Drift -VW 295-

t	Thrust pieces for pinion shaft bearing -VW 470-

t	Tube -30 - 14-

t	Thrust piece -2050-

t	Thrust plate -3005-

t	Tube -3296-

t	Torque wrench -V.A.G 1332-

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

t	Adapter -V.A.G 1582/1-

t	Adapter -V.A.G 1582/8-

t	-1-Internal puller -Kukko 21/8-

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

t  Inductive heater -VAS 6414- t  Feeler gauge

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). Table of adjustments → 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	Driving 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

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

q	Fitting on differential cage → Fig.

6 -	Differential cage1)

7 -

Bolt

q	60 Nm and turn 45° further

q

Renew

q	Tighten bolts in stages and in diagonal sequence until crown wheel makes full contact with differential cage. Then tighten to specified torque.

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

q	Pulling off → Fig.

q	Pressing on → Fig.

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

q	Pulling out → Fig.

q	Pressing in → Fig.

10 -

Shim „S1“

q	Note thickness

q	Table of adjustments → Chapter

11 -	Cover for final drive 1)

q	With O-ring

12 -	One-piece thrust washer

q	Lubricate with gear oil before installing

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	Drive out of differential cage with drift

q	Press in until 1.5 mm above differential cage

16 -	Planet pinion

q	Installing → Fig.

Pulling tapered roller bearing outer race (right-side) out of gearbox housing A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 56 ... 70 mm, e.g. -Kukko 21/8- –  After removing, check shims for damage.

Driving outer race for tapered roller bearing (right-side) into gearbox housing

Pulling off inner race for tapered roller bearing (right-side) –  Before setting up puller, place thrust pad -VW 447 H- on differential cage.

Pressing on tapered roller bearing inner race (left and right)   Note Use the same tools for pressing on tapered roller bearing inner race on left side and 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) –  Before setting up puller, place thrust pad -VW 447 H- on differential cage.

Pulling tapered roller bearing outer race (left-side) out of cover for final drive A -  Counter-support, e.g. -Kukko 22/2- B -  Internal puller 56 ... 70 mm, e.g. -Kukko 21/8- –  After removing, check shims for damage.

Pressing tapered roller bearing outer race (left-side) into cover for final drive.

Driving crown wheel off cage

Heating crown wheel to approx. 100 °C and installing –  When fitting crown wheel, use centralising pins -A- (shop-made tool) to locate.   WARNING Wear protective gloves. –  Allow to cool slightly before screwing in new securing bolts. –  Then tighten bolts in stages and in diagonal sequence until crown wheel makes full contact with differential cage. –  Then tighten bolts to specified torque → Item.

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