Differential, disassembling and assembling: Notes
WARNING: This page is about a different car, the 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.
Special tools and workshop equipment required
- VW 401 Pressure plate
- VW 402 Pressure plate
- VW 407 Press tool
- VW 408 A Press tool
- VW 447 H Thrust pad
- VW 447i Thrust pad
Special tools and equipment
- VW 472/1 Pressure piece
- 2050 Pressure piece
- 3138 Punch-out tool
- 3144 Sleeve
- 3296 Pipe
- VAG 1332 Torque wrench
Special tools and equipment
- VW 459 Pressing-out and pressing in 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:
Courtesy of VOLKSWAGEN UNITED STATES, INC.
- Removing and installing differential. Refer to Differential, removing and installing .
- Replace both tapered roller bearings together.
- When replacing parts marked 1) adjustments are required. Refer to Adjustment table .
1 - Transmission housing 1)
2 - Shim "S2"
- Make note of thickness
- Adjustment table. Refer to Adjustment table
3 - Outer race for right tapered roller bearing 1)
- Extracting. 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 Extracting 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 pinion (drive unit)
- Assigning by way of transmission code letters. Refer to Code letters, assignment of mechanical units, transmission ratios and capacities
- Driving out of housing using mandrel. See Driving ring gear out of housing
- Installing to differential housing HEATING RING GEAR TO APPROX. 100 ° C and installing 10
6 - Differential housing 1)
- Assigning by way of transmission code letters. Refer to Code letters, assignment of mechanical units, transmission ratios and capacities
- Assignment
7 - Bolt, 60 Nm plus 1/8 turn (45)
- Always replace
- Screw in bolts evenly and tighten to torque in diagonal sequence
8 - Inner race for left tapered roller bearing 1)
- Pulling off. See Extracting inner race for left tapered roller bearing
- Pressing on. See Mounting inner race for left tapered roller bearing
- Assignment
9 - Speedometer driving gear
- Removing and installing. Refer to Speedometer drive wheel, removing and installing
- Mount on differential carefully and without tilting. Do not use force, the driving gear could break
10 - Outer race for left tapered roller bearing 1)
- Driving out. See Driving outer race of left tapered roller bearing out of cover
- Pressing in. See Driving outer race of left tapered roller bearing into cover
- Assignment
11 - Shim "S1"
- Make note of thickness
- Adjustment table. Refer to Adjustment table
- Assignment
12 - Final drive cover 1)
- Apply a thin coat of sealing paste AMV 188 001 02 to sealing surfaces
- Assignment
13 - Large bevel gear
- Installing. See Installing bevel gears
14 - Differential bevel gear shaft
- Drive out with mandrel after removing spring pin
15 - Spring pin
- For securing bevel gear shaft
- With circumferential groove: Removing and installing. See Removing and installing spring pin
- Without circumferential groove: Drive out with mandrel
16 - Small bevel gear
- Installing. See Installing bevel gears
17 - One-piece thrust washer
- Apply gear oil on insertion