Differential Assembly

Inspect all thrust surfaces on differential case, cover, ring gear, pinion shaft and thrust washers. Replace all worn parts. Inspect gear teeth for burrs and excessive wear. Replace as necessary.
NOTE: If either pinion shaft or ring gear requires replacement, replace both as a set.
Position differential side gears, large thrust washers, dished thrust washers and pinion gear into differential case. Align pinion gear holes with holes in case. Drive pinion shaft through pinion gears. If pinion shaft does not fit tightly, replace it.
Place differential cover on differential case. Install 2 centering pins in opposite ring gear attaching bolt holes. Heat ring gear to about 212°F (100°C), then position it on housing. Remove centering pins and tighten attaching bolts.
NOTE: On 087 models with pressed on speedometer gear, new speedometer gear must be pressed onto differential case before side bearing installation.

Fig 1: Exploded View of Final Drive Assembly
Courtesy of AUDI OF AMERICA, INC.

Fig 2: Exploded View of 087 Model Differential Case Assembly
Courtesy of AUDI OF AMERICA, INC.

Fig 3: Measuring Pinion Shaft End Play
Courtesy of AUDI OF AMERICA, INC.

Turning drive pinion will cause incorrect reading.
Heat side bearings in hot oil and press them onto differential case and cover. Press side bearing outer races into position in side bearing adjusting rings.

NOTE: If original parts are reused, use same thickness pinion depth and bearing preload adjusting shims as were removed during disassembly.