Differential, removing and installing: Notes

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Differential, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Slide hammer-complete set VW771
Socket (27 mm) 3257
Torque wrench V.A.G1331
- 1 - Internal puller Kukko 21/5

NOTE:

Removing and installing is possible with the transmission installed.
The differential can be removed and installed without removing the selector mechanism, input shaft, pinion shaft/hollow shaft or bearing housing. These components must be removed if the differential needs to be adjusted.
Inspect polygon bearings for visible damage.
The polygon bearings can only be replaced together with the flange shaft.
If the polygon bearings do not run smoothly with the flange shaft removed, this does not necessarily indicate that the bearings are faulty. A test for noisy bearings can only be performed with the bearings installed.
A spacer ring is installed between the polygon bearing and the differential sun wheel on flange shafts with 30 mm spline diameter Flange shaft assembly , - Item4 -.
Adjustment work is required when replacing the parts marked with ¹⁾ . Table of adjustments → Table of adjustments

Fig 2: Differential Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Transmission housing ¹⁾

2 - Oil seal

Removing (left-side) Removing flange shaft oil seal (left-side)
Installing (left-side) Installing flange shaft oil seal (left-side)
Removing (right-side) Removing flange shaft oil seal (right-side)
Installing (right-side) Installing flange shaft oil seal (right-side)

3 - Circlip

Replace
Removing and installing Removing and installing circlip

4 - Spacer ring

Is only installed on flange shafts with a spline diameter of 30 mm
Remove with Internal puller 30 to 37 mm, e.g. Kukko 21/5
Installing Installing spacer ring

5 - Flange shaft

Removing (left-side) Removing flange shaft (left-side)
Removing (right-side) Remove right flange shaft
Drive in with drift VW295.
Flange shaft assembly Flange shaft assembly

6 - Differential with ring gear¹⁾

Disassembling and assembling → Differential, disassembling and assembling

7 - O-ring

Always replace
Lubricate with gear oil

8 - Cover for final drive ¹⁾

9 - TORX bolt, 20 Nm plus an additional 90° ¹ /₄ turn