Differential, Disassembling And Assembling

Special tools and workshop equipment required

Seal Installer - Crankshaft: VW204B
Bearing/Bushing Installer - Multiple Use: VW295
Press Plate: VW401
Press Plate: VW402
Press Piece - Multiple Use: VW412
Press Piece - Multiple Use: VW447H
Bearing Installer - Needle Bearing: 30-506B
Press Piece - Multiple Use: 40-105
Press Piece - Multiple Use: 3005
Bearing Installer - Wheel Bearing: 3144
Press Piece - Reverse Gear Syncro: 3296
Bearing Installer - Wheel Bearing: 3345
Puller - Grease Cap: VW637/2
Thrust Sleeve: T10299
Puller - Taper Roller Bearing: VAG1582
Puller - Taper Roller Bearing - Adapter 16A: VAG1582/16A
Puller - Taper Roller Bearing - Adapter 17: VAG1582/17
Inductive Heater: VAS6414
-4- Internal Puller (Kukko 21/89): VAS251619
-4- Puller - Roller Bearing (Kukko 21-8): VAS6775
-3- Counter Support: VAS251623
-1- Counter Support (Kukko 22/4): VAS251625

Before performing assembly work on the differential, drain the transmission fluid, secure the transmission on the assembly stand, and remove the flywheel with the right flange shaft. Refer to FLYWHEEL, REMOVING AND INSTALLING .

-- Secure the transmission on the transmission holder. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

-- Remove the differential. Refer to DIFFERENTIAL, REMOVING AND INSTALLING .

Left Tapered Roller Bearing Outer Race, Removing from Transmission Housing

Fig 1: Left Tapered Roller Bearing Outer Race, Removing from Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

Counter Support: VAS251623
Puller - Roller Bearing (Kukko 21-8): VAS6775

Use the Puller - Roller Bearing: VAS6775 so that it can be positioned under the outer race.

-- Check the shim for damage after removing.

Left Tapered Roller Bearing Outer Race, Driving into Transmission Housing

Fig 2: Driving Outer Race For Tapered Roller Bearing With Shim Into Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

Install the shim in the transmission housing.

Removing the Left Tapered Roller Bearing Inner Race

Fig 3: Removing Left Tapered Bearing Inner Race (Efficiency Bearing)

Courtesy of AUDI OF AMERICA, LLC

-- Before installing the puller, mount the Press Piece - Multiple Use: 40-105 onto the differential housing.

Left Tapered Roller Bearing Inner Race, Installing

Fig 4: Installing Left Tapered Bearing Inner Race (Normal And Efficiency Bearing)

Courtesy of AUDI OF AMERICA, LLC

Tip:

Wear safety gloves.

-- Support the differential on the bottom using the Bearing Installer - Needle Bearing: 30-506B . Do not place on the inner race.

-- Warn the inner race using the Inductive Heater: VAS6414 to 100 °C (212 °F) and press it in.

Right Angular Contact Ball Bearing Inner Race, Removing

Fig 5: Removing Right Angular Contact Ball Bearing Inner Race (Efficiency Bearing)

Courtesy of AUDI OF AMERICA, LLC

-- Carefully clamp the differential in a vise with the protective jaws -A-.

-- Remove bearing cage with ball bearings from the inner race.

-- Before installing the puller, set Press Piece - Multiple Use: VW447H onto differential housing.

Right Angular Contact Ball Bearing Inner Race, Installing

Fig 6: Press on the right tapered bearing inner race or the angular contact ball bearing inner race.

Courtesy of AUDI OF AMERICA, LLC

-- Support the differential on the bottom using the Bearing Installer - Needle Bearing: 30-506B . Do not place on the inner race.

Tip:

A tapered roller bearing inner race is shown. Installing the angular contact ball bearing inner race is identical.

-- Heat inner race to approximately 100 °C (212 °F), fit in position and press in.

Angular Contact Ball Bearing Outer Race, Loosening Slightly from Bearing Seat

Fig 7: Prying Outer Race Tapered Bearing

Courtesy of AUDI OF AMERICA, LLC

Tip:

Warm the final drive cover to approximately 100 °C (212 °F) with the Wiring Harness Repair Set - Hot Air Blower: VAS1978/14A so that the outer race for the angular contact ball bearing can be more easily removed.

-- Then press the angular contact ball bearing outer race slightly out of the bearing seat by gradually installing the Puller - Grease Cap: VW637/2 in small steps and pressing in the direction of -arrow-.

-- Then remove the angular contact ball bearing outer race from the final drive cover. Refer to Fig 8.

Angular Contact Ball Bearing Outer Race 3, Removing from Final Drive Cover

Fig 8: Angular Contact Ball Bearing Outer Race -3-, Removing from Final Drive Cover

Courtesy of AUDI OF AMERICA, LLC

Counter Support (Kukko 22/4): VAS251625
Internal Puller (Kukko 21/89): VAS251619

Installing the Angular Contact Ball Bearing Outer Race into the Final Drive Cover

Fig 9: Identifying Outer Race Tapered Bearing, Installation

Courtesy of AUDI OF AMERICA, LLC

-- Install the shim in the final drive cover.

-- Press the angular contact ball bearing outer race in all the way. The larger diameter of the Seal Installer - Crankshaft: VW204B faces the outer race.

-- Support the final drive cover by supporting the Bearing Installer - Wheel Bearing: 3345 directly under the bearing mount.