Differential, disassembling and assembling: Notes

Special tools, testers and auxiliary items required: 

• Drift VW 295
• Thrust plate VW 401
• Thrust plate VW 402
• Press tool VW 412
• Installing tool VW 459/2
• Thrust plate 30-205
• Mandrel 30-505
• Press tool 40-21
• Thrust plate 40-105
• Thrust pad 3062
• Drift 3138
• Taper roller bearing puller V.A.G 1582
• Grip V.A.G 1582/3
• Grip V.A.G 1582/6

1. Transmission housing  ¹⁾ 
2. Shim "S2" 
   • Note thickness
   • Adjustment overview. See ADJUSTMENT OVERVIEW .
3. Outer race for small taper roller bearing  ¹⁾ 
   • Driving out. See DRIVING OUTER RACE FOR SMALL TAPER ROLLER BEARING OUT OF TRANSMISSION HOUSING .
   • Driving in. See DRIVING OUTER RACE FOR SMALL TAPER ROLLER BEARING INTO TRANSMISSION HOUSING .
4. Inner race for small taper roller bearing  ¹⁾ 
   • Pulling out. See PULLING INNER RACE FOR SMALL TAPER ROLLER BEARING OUT OF HOUSING .
   • Pressing in. See PRESSING ON INNER RACE FOR SMALL TAPER ROLLER BEARING .
   • Low friction bearing; do not oil when measuring frictional torque
5. Ring gear  ¹⁾ 
   • Paired with drive pinion (final drive set)
   • Removing. See DRIVING RING GEAR OFF HOUSING .
   • Installing. See INSTALLING RING GEAR .
6. Differential housing  ¹⁾ 
7. Ring gear bolt, 60 Nm + 45 ° further 
   • Always replace
   • Use only genuine bolts
8. Inner race for large taper roller bearing  ¹⁾ 
   • Pulling off. See PULLING INNER RACE FOR LARGE TAPER ROLLER BEARING OFF HOUSING .
   • Pressing on. See PRESSING ON INNER RACE FOR LARGE TAPER ROLLER BEARING .
   • Low friction bearing; do not oil when measuring frictional torque.
9. Drive wheel 
   • For speedometer sender
   • Removing and installing. See SPEEDOMETER SENDER -G22- AND DRIVE WHEEL FOR SPEEDOMETER SENDER, REMOVING AND INSTALLING .
   • Fit the drive wheel carefully onto the differential, making sure that it is kept straight. Do not use force; the drive wheel can break easily
   • Installation position: shoulder (arrow) towards differential
10. Outer race for large taper roller bearing  ¹⁾ 
    • Driving out. See DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING OUT OF COVER .
    • Driving in. See DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING INTO COVER .
11. Shim "S1" 
    • Note thickness
    • Adjustment overview. See ADJUSTMENT OVERVIEW .
12. Cover for final drive  ¹⁾ 
    • With O-ring
    • Replace O-ring
    • Oil O-ring before installing
13. Shims 
    • Re-determining thickness. See ADJUSTING PLANET WHEELS AND SUN WHEELS .
14. Sun wheels 
    • Adjusting. See ADJUSTING PLANET WHEELS AND SUN WHEELS .
15. Threaded piece 
16. Thrust washer 
    • Check for cracks and chipping
17. Planet wheels 
    • Installing. See INSTALLING PLANET WHEELS AND SUN WHEELS .
18. Shaft for planet wheels 
    • Drive out with drift after removing spring pin
    • Before driving in, align thrust washers
19. Spring pin 
    • Drive in flush
Fig 1: Exploded View Of Front Differential Assembly
Courtesy of AUDI OF AMERICA, INC.

Prepare the following special tools and test equipment: 

• VW401 thrust plate
• VW402 thrust plate
• VW407 punch
• VW412 punch
• VW295 needle bearing drift
• VW408A punch
  Fig 1: Identifying Special Tools (1 Of 2)

  Courtesy of AUDI OF AMERICA, INC.
• VW442 thrust pad
• Sleeve 40-21
• Thrust piece 40-105
• Thrust plate 2050
• Drift 3138
• Kukko 44/2 two-arm puller
  Fig 2: Identifying Special Tools (2 Of 2)

  Courtesy of AUDI OF AMERICA, INC.
• VAG1582 taper roller bearing puller
  Fig 3: Identifying VAG1582 Taper Roller Bearing Puller Tool

  Courtesy of AUDI OF AMERICA, INC.
• VAG1582/6 attachment to VAG1582
  Fig 4: Identifying VAG1582/6 Attachment To VAG1582 Tool

  Courtesy of AUDI OF AMERICA, INC.

1. Cover for final drive  ¹⁾ 
2. O-ring 
   • Replace
   • Lubricate with oil when installing
3. Final drive housing  ¹⁾ 
4. Shim "S1" 
   • Note thickness
   • Adjustment overview. See ADJUSTMENT OVERVIEW .
5. Outer race for small taper roller bearing  ¹⁾ 
   • Knocking out. See KNOCKING OUTER RACE OF SMALL TAPER ROLLER BEARING OUT OF HOUSING .
   • Pressing in. See PRESSING OUTER RACE OF SMALL TAPER ROLLER BEARING INTO TRANSMISSION HOUSING (PRESS TO STOP) .
6. Inner race for small taper roller bearing  ¹⁾ 
   • Pulling out. See PULLING OFF INNER RACE FOR SMALL TAPER ROLLER BEARING .
   • Pressing in. See PRESSING ON INNER RACE FOR SMALL TAPER ROLLER BEARING .
7. Bolt, 60 Nm + turn 45 ° further 
   • REPLACE bolt
   • Allocation

     See Parts catalog 

   • Lightly tighten bolts then tighten diagonally to correct torque
8. Differential housing  ¹⁾ 
9. Ring gear  ¹⁾ 
   • Paired with drive pinion (final drive set)
   • Select correct version according to code letters.

     See Parts catalog 

   • Drive off housing with a punch. See DRIVING RING GEAR OFF HOUSING .
   • Installing on differential housing. See INSTALLING RING GEAR .
10. Spring pin 
    • For securing planet pinion axis shaft
    • Drive in flush
11. Inner race for large taper roller bearing  ¹⁾ 
    • Pulling off. See PULLING OFF INNER RACE FOR LARGE TAPER ROLLER BEARING .
    • Pressing on. See PRESSING ON INNER RACE FOR LARGE TAPER ROLLER BEARING .
12. Outer race for large taper roller bearing  ¹⁾ 
    • Driving out DRIVING OUTER RACE FOR LARGE TAPER ROLLER BEARING OUT OF COVER .
    • Pressing in. See PRESSING OUTER RACE FOR LARGE TAPER ROLLER BEARING INTO COVER .
13. Shim "S2" 
    • Note thickness
    • Adjustment overview. See ADJUSTMENT OVERVIEW .
14. Threaded piece 
15. Sun wheel 
    • Installing. See INSTALLING SUN WHEELS AND PLANET PINIONS .
    • Adjusting. See ADJUSTING SUN WHEELS AND PLANET PINIONS .
16. Planet pinion 
    • Installing. See INSTALLING SUN WHEELS AND PLANET PINIONS .
17. Planet pinion axis shaft 
    • Knock out with drift
18. Shim 
    • Re-determining thickness. See ADJUSTING SUN WHEELS AND PLANET PINIONS .
19. Thrust washer 
    • Check for cracks