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 408 A-

t	Press tool -VW 411-

t	Press tool -VW 412-

t	Thrust plate -VW 447 H-

t	Thrust pieces for pinion shaft bearing -VW 470-

t	Tube -30 - 14-

t	Extension -30 - 23-

t	Support -40 - 103-

t	Thrust piece -2050-

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

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

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

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

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 set)

q	Allocate according to gearbox code letters via → Electronic parts catalogue “ETKA”.

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

q	Fitting onto differential cage → Fig.

6 -	Differential cage1)

7 -	Bolt, 60 Nm + 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.

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 drive1)

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	For securing differential pinion pin

q	Is sheared off on removal → Fig.

q	Drive in flush

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 tapered roller bearing inner races –  Before setting up the puller, place thrust pad -VW 447 H- on differential cage.   Note The procedure for pulling tapered roller bearing inner races (left and right) off differential is the same for both sides.

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 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 to specified torque.

Removing differential pinion pin The spring pin is sheared off when pressing out. –  Drive out parts of spring pin remaining in differential cage and differential pinion pin.

Installing differential bevel gears –  Lubricate one-piece thrust washer with gear oil and install. –  Insert sun wheels. –  Insert planet pinions offset 180° and rotate into position -arrow-. –  Align drillings of one-piece thrust washer, planet pinions and differential cage. –  Drive differential pinion pin into final position and secure.