AUDI A4 1997 B5 / 1.G 01A Transmission Differential Remove And Install Workshop Manual

39-114


Differential, removing and
installing Notes:

Refer to general repair instructions Page 00
-
14
.
Mounting final drive to repair stand Page 39
-
110
.
Adjustments are required when replacing
components marked with 1) List of
adjustments, Page 39
-149
.
1 -
Breather sleeve
With rubber valveInstallation position Fig. 3
2 -
Final drive housing1)
With pinion shaftRemoving and installing drive pinion
Page 39
-134

3 -
Large tapered roller bearing outer race1)
Removing Page 39
-129, Fig. 7
Pressing in Page 39
-130, Fig. 8
4 -
Shim S1
Note thickness
Pa
ge 1 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14

List of adjustments Page 39
-149
Pa
ge 2 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14

39-115


5 -
Final drive cover1)
Always replace O-ringWith O-ringLubricate O-ring with oil when installing
6 -
Torx bolt 25 Nm (18 ft lb)
7 -
Right seal Replacing Page 39
-100
8 -
Socket-head bolt
25 Nm (18 ft lb)
9 -
Drive flange, right Removing and installing Fig. 1
10 -
Oil filler plug
35 Nm (26 ft lb)
11 -
Differential with ring gear1) Disassembling and assembling Page 39
-121

12 -
Oil drain plug
35 Nm (26 ft lb)
13 -
Bushing
Pa
ge 3 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14

Holds magnet in positionDrive in onto stop
Pa
ge 4 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14

39-116


14 -
Magnet
15 -
Small tapered roller bearing outer race 1)
Removing Page 39
-126, Fig. 1
Installing Fig. 2, Page 39
-126
16 -
Shim S2
Note thicknessList of adjustments Page 39
-149
17 -
Left seal
Replacing Page 39
-100
18 -
Drive flange, left
Removing and installing Fig. 1
19 -
Socket-head bolt
25 Nm (18 ft lb)
20 -
Cover Installing Fig. 2
Pa
ge 5 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14

39-117


Fig. 1 Removing and installing drive flange
- To loosen mounting bolt, screw in 2 bolts in drive flange and counter-
hold using pry bar.
- Pull out drive flange using screwed in bolts.

Fig. 2 Press in cover onto stop
Pa
ge 6 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14

39-118


The breather sleeve should project 13 mm (0.512 in.) dimension -a- out of
final drive housing after pressing in.
The slot in the rubber valve should be in line with the direction of travel. Fig. 3 Position of breather sleeve
Pa
ge 7 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14

39-119

Removing

Final drive removed

Special tools and equipment
VAG1306 drip tray
Secure complete final drive to repair stand using
VW540 bracket Page 39
-110
.
Place drip tray under final drive and drain gear
oil.

- Remove left and right drive flanges:
- To loosen mounting bolt, screw two bolts into drive flange and counter-
hold with pry bar.
- Mark drive flanges (left and right).
- Pull out drive flange using screwed in bolts.
- Remove mounting bolts from final drive cover.
- Remove final drive cover from final drive housing and remove
differential.
Pa
ge 8 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14

39-120

Installing
Install in reverse order of removal, note the
following:

- Install differential.

- Replace O-ring for final drive cover and lubricate
before installing.

- Install final drive cover on final drive housing and
tighten in diagonal sequence to 25 Nm (18 ft lb).

- Replace seals for drive flange Page 39
-
100
.

- Fill space between sealing lip and dust lip with
gear oil

- Install drive flanges and tighten 25 Nm (18 ft lb).
- Top off gear oil in final drive and check oil level Page 39
-84
.Pa
ge 9 of 9 Differential, removin
g and installin
g
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.39.14