Disassembly And Assembly: Differential

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 408 A
Thrust Disc VW 412
Assembly Tool T40033/3
Thrust Piece T10266
Assembly Device 3291/2
Thrust Pad VW 472/1
Thrust Piece 40-105
Pressure Sleeve T10299
Kukko Extractor 56-70 mm 21/8
Kukko Support 22/2
2-Arm Puller 20/10

NOTE:

Heat the inner race/tapered roller bearing to 100 °C (212 °F) before installing.

Replace both tapered roller bearings together.

Adjust the differential when replacing the differential housing. Refer to DIFFERENTIAL, ADJUSTING .

Fig 1: Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing.

Courtesy of AUDI OF AMERICA, LLC

A - Support, for example 22/2

B - Extractor 56-70 mm, for example, 21/8

Fig 2: Installing Outer Race/Tapered Roller Bearing Into Transmission Housing

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-- Support the transmission housing using the assembly device 3291/2 directly under the bearing mount.

Fig 3: Removing Inner Race/Tapered Roller Bearing In Transmission Housing And Bearing In Clutch Housing

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Both tapered roller bearing inner races are pulled off from the differential housing in the same way.

-- Tension the puller -A- in the area of the flattened side of differential housing below inner race.

A - 2-arm puller, for example 20/10

Fig 4: Installing Inner Race/Tapered Roller Bearing In Transmission Housing And Bearing In Clutch Housing

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Both differential housing tapered roller bearing inner races are installed in the same way.

Fig 5: Removing Outer Race/Tapered Roller Bearing From Clutch Housing

Courtesy of AUDI OF AMERICA, LLC

A - Support, for example 22/2

B - Extractor 56-70 mm, for example 21/8

NOTE:

After removing, replace the damaged shim.

Fig 6: Installing Outer Race/Tapered Roller Bearing Into Clutch Housing

Courtesy of AUDI OF AMERICA, LLC

-- Install the washer and the shim beforehand.

NOTE:

Note the installed position of the washer, the shoulder on inner diameter points toward seal.

Fig 7: Driving Out Spring Pin With Chisel, Inserting Chisel Into Circumferential Groove

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-- Cover the inner race/tapered roller bearing in order to prevent possible damage and entry of shavings.

-- Remove the adapter sleeve using a chisel.

Fig 8: Installing Spring Pin For Differential Bevel Gear Axle

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-- Align the hole in the differential bevel gear axle to the hole in the differential housing.

-- Install the adapter sleeve to dimension -a- = 3 +/- 0.5 mm using a drift -1-.

Fig 9: Identifying Thrust Washer Union And Differential Housing

Courtesy of AUDI OF AMERICA, LLC

-- Coat the thrust washer union with transmission fluid.

-- Install the thrust washer union so that the ridge -A- fits into the groove -B- in the differential housing.

Fig 10: Differential Bevel Gears And Differential Bevel Gear Axle, Installation

Courtesy of AUDI OF AMERICA, LLC

-- Insert thrust washer union with transmission fluid. Refer to Fig 9.

-- Insert both large differential bevel gears and secure (for example, with stub shaft).

-- Insert the small differential planetary gears 180° offset and pivot them into position.

-- Press the differential bevel gear -arrow A- up to the first small differential bevel gear.

-- Insert the threaded pieces -arrow B- into the large differential planetary gears.

Installed position: Collar toward the differential bevel gear

-- Drive the differential planetary gear axle into its final position and secure it with the spring pin. Refer to Fig 8.