Differential, disassembling and assembling: Notes

WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Differential, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

VW 401 Thrust plate
VW 402 Thrust plate
VW 407 Press tool
VW 408 A Press tool

VW 447 H Thrust disk
VW 447 i Thrust disk

Fig 2: Identifying Special Tools - Differential, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

VW 472/1 Thrust piece
2050 Thrust piece
3138 Drift
3144 Sleeve

3296 Tube
VAG 1332 Torque wrench

Fig 3: Identifying Special Tools - Differential, Disassembling And Assembling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

VW 459 Installation and removal tool
1 - Kukko 21/7 Internal puller
3 - Kukko 204/2 Puller
4 - Kukko 22/2 Counter-support

Kukko 44-2 Two-arm puller

NOTE:

Fig 4: Differential, Disassembling And Assembling, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing and installing differential. Refer to Differential, removing and installing .
Replace both tapered roller bearings.
Adjustments are required when replacing components marked 1).

1 - Transmission housing 1)

2 - Shim "S2"

Note thickness

3 - Outer race for right tapered roller bearing 1)

Pulling out. See Extracting tapered roller bearing outer race from transmission housing
Pressing in. See Pressing tapered roller bearing outer race into transmission housing

4 - Inner race for right tapered roller bearing 1)

Pulling off. See Pulling off inner race for right tapered roller bearing
Pressing on. See Pressing on inner race for right tapered roller bearing

5 - Ring gear 1)

Paired with drive pinion (final drive set)
Select according to transmission code letters. Refer to Code letters, application, ratios, capacities
With a mandrel drive off housing. See Driving ring gear off housing
Install to differential housing. See HEAT THE RING GEAR TO APPROX. 100 ° C and position

6 - Differential housing 1)

Select according to transmission code letters. Refer to Code letters, application, ratios, capacities
Allocation

7 - Bolt - 60 Nm + turn 45 ° further

Always replace
Lightly tighten bolts then tighten diagonally to specified torque.

8 - Inner race for left tapered roller bearing 1)

Pulling off. See Pulling off inner race for left tapered roller bearing
Allocation

9 - Speedometer drive wheel

Removing and installing. Refer to Speedometer drive wheel, removing and installing
Carefully install the drive wheel onto the differential, make sure that it is kept straight. The drive wheel can break using excessive force

10 - Outer race for left tapered roller bearing 1)

Tapping out. See Driving out outer race for left tapered roller bearing out of cover
Pressing in. See Driving outer race for left tapered roller bearing into cover
Allocation

11 - Shim "S1"

Note thickness

12 - Cover for final drive 1)

Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces

13 - Large differential bevel gear

Installing. See Installing bevel gears

14 - Shaft for bevel gears

Remove spring sleeve knocking out with drift

15 - Spring pin

For securing shaft for bevel gears
With annular groove: Removing and installing. See Removing and installing spring sleeve
Without annular groove: Drive out with mandrel

16 - Small differential bevel gear

Installing. See Installing bevel gears

17 - One-piece thrust washer

When installing coat with transmission oil