Final Drive, Adjusting When Replacing Differential Or Differential Bearing: Notes

WARNING: This page is about a different car, the 2024 Audi A4 allroad. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Seal Installer - Crankshaft:VW 204 B
Measuring Set - End Gauge:VW 385/33
Dial Indicator Holder:VW 387
Press Plate:VW 402
Press Piece - Multiple Use:VW 412
Bearing Installer - Wheel Bearing:3345

Special tools and workshop equipment required

Measuring Lever:VW 388
Crown Wheel Adjusting Tool:VW 521
Press Piece - Multiple Use:3005
Bearing Installer - Wheel Bearing:3345
Drive Axle Wedge Tool:T10161
Dial Gauge for example Dial Gauge - 0-3mm:VAS 6080A

TIP:

Careful adjustment of the differential is important for service life and smooth running of final drive.

Adjusting the final drive (differential) is required if the differential and the differential bearing are being replaced.
The drive pinion remains installed, for this reason the adjustment backlash must always be achieved. Otherwise the drive train will be damaged!
The transmission is secured to the assembly stand and the flywheel with the right flange shaft is removed.

Total Shim Thickness "S _total " for Shims "S ₁ " + "S ₂ ", Determining

-- Remove the left tapered roller bearing outer race from the transmission housing. Refer to Figure.

-- Drive the new outer race for left tapered roller bearing with the old shim "S₂ " with the example thickness of 1.05 mm into the transmission housing.

Fig 1: Driving Outer Race For Tapered Roller Bearing With Shim Into Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

For the initial measurement, install the old shim "S₂ " with a thickness for example of 1.05 mm. This will be indicated by "S₂ *" in the following. After determining the torsional backlash, "S₂ *" is replaced by final "S ₂ ".

-- Press in the new outer race for the right angular contact ball bearing with the old shim "S ₁ " in for example of 1.21 mm in the final drive cover. The larger diameter of the Seal Installer - Crankshaft:VW 204 B faces the outer race.

Fig 2: Identifying Outer Race Tapered Bearing, Installation

Courtesy of AUDI OF AMERICA, LLC

-- Insert the differential into the transmission housing.

CAUTION:

Danger of causing damage to the gear set.

Check the torsional backlash when tightening the final drive cover. Some play must always be present.
If the transmission is disassembled, the play at the pinion can be checked by turning back and forth.
If transmission is not disassembled, install the Crown Wheel Adjusting Tool:VW 521 and check play.

-- Fasten the final drive cover carefully with four bolts diagonally to 20 Nm.

Fig 3: Crown Wheel Adjusting Tool VW521

Courtesy of AUDI OF AMERICA, LLC

Place the Positioning Tolerance Shell:VW 521/13 with the smaller outer diameter -arrow- on the Ring Gear Locking Sleeve: VW 521/4 .

-- Insert the Crown Wheel Adjusting Tool:VW 521 and turn the differential five turns each in both directions, so that the bearings set.

Fig 4: Inserting Adjusting Tool VW521/4 And VW521/13 Into Differential

Courtesy of AUDI OF AMERICA, LLC

-- Remove the Crown Wheel Adjusting Tool:VW 521 and install the measuring tools on the transmission housing as follows:

Fig 5: Checking Tapered Roller Bearing Pre-Load

Courtesy of AUDI OF AMERICA, LLC

-- Attach the Dial Gauge Holder:VW 387 to the threaded hole in the transmission housing with the bolt -A-.

-- Place the Dial Gauge Extension on the center of the Measuring Set - End Gauge:VW 385/33 .

-- Set the Dial Gauge for example Dial Indicator:VAS 6080A to >>0<< with 1 mm of pretension.

-- Loosen the four bolts -arrows- diagonally one turn.

-- Read the measured value on the dial gauge.

Specified value: 0.25 to 0.30 mm

-- If the measure value is not obtained or no torsional backlash is felt, then correct the thickness of the shims "S₁ " and "S₂ ".

Allocate adjustment shims according to the Parts Information.