Differential, disassembling and assembling: Notes

WARNING: This page does not describe the selected car, but rather 17 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Differential, Disassembling And Assembling (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The following special tools and testing devices are required:

Thrust plate VW 401
Thrust plate VW 402
Punch VW 407
Thrust disc VW 412

Needle bearing drift VW 295
Punch VW 408 A

Fig 2: Identifying Special Tools - Differential, Disassembling And Assembling (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thrust pad VW 442
Sleeve 40-21
Thrust piece 40-105
Thrust plate 2050

Drift 3138
Two-arm puller Kukko 44/2

Fig 3: Tapered Roller Bearing Puller V.A.G 1582

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Taper roller bearing extractor V.A.G 1582

Fig 4: Tapered Roller Bearing Puller V.A.G 1582

Courtesy of VOLKSWAGEN UNITED STATES, INC.

V.A.G 1582/6

NOTE:

Fig 5: Rear Differential, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

General repair instructions. Refer to Repair instructions .
Secure final drive on a repair stand. Refer to Secure complete rear final drive on a repair stand with bracket VW 540 .
Replace both taper roller bearings together.
When replacing the parts marked with 1) adjustment work is required. Refer to Adjustment overview .

1 - Cover for final drive 1)

2 - O-ring

Replace
Insert with oil

3 - Final drive housing 1)

4 - Shim "S1"

Note thickness
Adjustment overview. Refer to Adjustment overview .

5 - Outer race for small taper roller bearing 1)

Tapping out. See Figure
Pressing in. See Figure

6 - Inner race for small taper roller bearing 1)

Pulling off. See Figure
Pressing on. See Figure

7 - Bolt - 60 Nm plus an additional45°1/4 turn

Replace
Allocation

Lightly tighten bolts then tighten diagonally to specified torque.

8 - Differential housing 1)

9 - Ring gear 1)

Paired with pinion shaft (final drive set)
Allocation based on transmission code letters

Drive off housing with a drift. See Figure
Install to differential housing. See Figure

10 - Spring pin

For securing shaft for bevel gears
Drive in flush

11 - Inner race for large taper roller bearing 1)

Pulling off. See Figure
Pressing on. See Figure

12 - Outer race for large taper roller bearing 1)

Tapping out. See Figure
Pressing in. See Figure

13 - Shim "S2"

Note thickness
Adjustment overview. Refer to Adjustment overview .

14 - Threaded piece

15 - Large bevel gear

Installing. See Figure
Adjusting. See Figure

16 - Small bevel gear

Installing. See Figure

17 - Shaft for planet wheels

Drive out with drift

18 - Adjustment shim

Redefine thickness. See Figure

19 - Thrust washer

Check for cracks