AUDI A4 1996 B5 / 1.G 01A Transmission Torsen Differential Assembly Workshop Manual

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Torsen differential,
disassembling and
assembling

Special tools and equipment

VW401 and VW402 thrust plate
VW407 punch
VW412 punch
VW416B tube
VW421 tube
VW439 guide pin
VW519 sleeve
VW681 extractor lever
VW771/15 threaded piece from VW771 slide
hammer-complete set
40-21 sleeve
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2040 press tube
3002 pressure piece
Kukko 17/2 separating tool
Kukko 21/4 extractor
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1 -
Transmission housing
2 -
Spring
3 -
Front needle bearing
Pulling out Fig. 8Installation position Fig. 9Pressing in Fig. 11
4 -
Torsen differential
Do not disassemblePress out after removing flange shaft
Fig. 3

Replace if damagedPressing in Fig. 12
5 -
Rear needle bearing
Pulling out Fig. 8Installation position Fig. 10Pressing in Fig. 11
6 -
Ball bearing
For Torsen differentialPressing off Fig. 4Pressing on Fig. 5
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7 -
Circlip
8 -
Circlip
Remove and install together with flange
shaft Fig. 2

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9 -
Ball bearing
For flange shaftPressing out Fig. 6Pressing in Fig. 7
10 -
Torsen differential cover
11 -
Circlip
12 -
Plug
Removing Fig. 1
13 -
O-ring
Always replaceLubricate before installing
14 -
Torx bolt 22 Nm (16 ft lb)
15 -
Seal Pull out using VW681 extractor leverDriving in Fig. 13
16 -
Vibration dampener
17 -
Circlip
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18 -
Torx bolt
Always replace35 Nm (26 ft lb)Self-locking
19 -
Flange shaft Removing and installing Fig. 2
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Fig. 1 Removing plug
- Remove circlip -A-.
- Screw M8 bolt into thread of plug -B-.
- Remove plug -B- using bolt.

Fig. 2 Removing and installing flange shaft
- Spread circlip and pull out flange shaft.
- When installing flange shaft, circlip must be installed at same time.
The circlip must be fully seated in the base of the groove.
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Fig. 3 Removing Torsen differential
- Position 3002 thrust piece directly on Torsen differential through
opening (arrow).

Fig. 4 Pressing off ball bearing from Torsen differential
A - Separating tool 22-115 mm, e.g. Kukko 17/2
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Fig. 5 Pressing ball bearing onto Torsen differential
- Press ball bearing on until stop is reached.

Fig. 6 Pressing out ball bearing for flange shaft
- Remove circlip before pressing out bearing.
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Fig. 7 Pressing in ball bearing for flange shaft
- Install circlip after pressing in ball bearing.

Both needle bearings in the Torsen differential are removed using the
same puller. Fig. 8 Pulling out needle bearing
A - Extractor 22-28 mm, e.g. Kukko 21/4
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