AUDI A6 1996 C5 / 2.G 01E Transmission Final Drive Differential Assembly Workshop Manual

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Differential, disassembling
and assembling

Special tools, testers and auxiliary items

Drift VW 295
Press plate VW 401
Press plate VW 402
Press tool VW 407
Press tool VW 408 A
Press tool VW 412
Press tool VW 442
Press tool 40-21
Thrust plate 40-105
Thrust pad 2050

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Drift 3138
Tapered roller bearing puller V.A.G 1582 and
V.A.G 1582/6
Two-arm puller Kukko 44/2
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Note:

General repair instructions Page 00
-11
.
Replace both tapered roller bearings of the
differential together. Use same make if possible.
Adjustments are required when replacing
components marked 1) Page 39
-150
,
Adjustment overview
1 -
Cover for final drive
1)
2 -
O-ring
Always replaceInsert with oil
3 -
Final drive housing
1)
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Parts catalog 4 -
Shim "S2"
Note thicknessAdjustment overview Page 39
-150
5 -
Outer race for small tapered roller bearing
1) Knocking out Fig. 1Pressing in Fig. 2
6 -
Inner race for small tapered roller bearing
1) Pulling out Fig. 3Pressing in Fig. 4
7 -
Bolt, 60 Nm + turn 45 further
Always replaceAllocationLightly tighten bolts then tighten diagonally
to correct torque
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Parts catalog 8 -
Differential housing
1)
9 -
Ring gear
1)
Paired with drive pinion (final drive set)Select correct version according to code
letters Drive off housing with a punch Fig. 9Installing on differential housing Fig. 10
10 -
Spring pin
For securing planet pinion axis shaftDrive in flush
11 -
Inner race for large tapered roller bearing
1) Pulling off Fig. 5Pressing on Fig. 6
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12 -
Outer race for large tapered roller bearing
1) Driving out Fig. 7Pressing in Fig. 8
13 -
Shim "S1"
Note thicknessAdjustment overview Page 39
-150
14 -
Threaded piece
15 -
Sun wheel
Installing Fig. 11Adjusting Fig. 12
16 -
Planet pinion
Installing Fig. 11
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17 -
Planet pinion axis shaft
Knock out with driftDrive in carefully so that the thrust washers
are not damaged Secure with spring pin - 10 -
18 -
Shim Re-determining thickness Fig. 12
19 -
Thrust washer
Check for cracks
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Fig. 1 Knocking outer race of small tapered roller bearing out of
housing
- After removing check shims for damage.

Fig. 2 Pressing outer race of small tapered roller bearing into
housing (press against stop)
- Position outer race using VW 295 and light even blows with a hammer.
- Drive in onto stop as shown in illustration.
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Fig. 3 Pulling off inner race for small tapered roller bearing
A - Two arm puller, e.g. Kukko 44/2
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CAUTION!
Wear protective gloves. Fig. 4 Pressing on inner race for small tapered roller bearing
-
Heat bearing to approx. 100 C, fit in position and press home.

Fig. 5 Pulling off inner race for large tapered roller bearing
- Before fitting extractor position press piece 40-105 on differential
housing.
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