differential AUDI A4 1999 B5 / 1.G 01A Transmission Assembly Workshop Manual

34-44


8 -
Torsen differential
Can only be serviced by manufacturerRemoving and installing together with
cover Page 34
-39

9 -
Bearing
10 -
Bearing
11 -
Flange shaft
12 -
Torsen differential cover
13 -
Compression spring
Between Torsen differential and hollow
shaft
14 -
Input shaft Disassembling and assembling Page 35
-1
15 -
Transmission cover
Pa
ge 2 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5

34-45


16 -
Transmission housing
17 -
Ball bearing
Adjusting thickness Input shaft,
adjusting Page 35
-17

18 -
Differential
Removing and installing Page 39
-16
Disassembling and assembling Page 39
-21

19 -
Drive pinion
Disassembling and assembling drive pinion
and hollow shaft Page 35
-21

20 -
Radial tapered roller bearing
Adjusting Page 39
-39
21 -
Hollow shaft
Disassembling and assembling drive pinion
and hollow shaft Page 35
-21

Pa
ge 3 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5

34-46


Assembly overview

I - Input shaft ball bearing and multi-
function switch, removing and installing
Page 34
-47

II - Input shaft, drive pinion, hollow shaft,
selector rods, transmission cover and
Torsen differential cover, removing and
installing Page 34
-51

Pa
ge 4 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5

34-47


Input shaft ball bearing and multi-function
switch, removing and installing

1 -
Transmission housing
With differential and flange shaftsRemoving and installing flange shafts
Page 39
-1
Removing and installing differential
Page 39
-16

Removing and installing speedometer
Vehicle Speed Sensor (VSS) Page 39
-
13

Removing and installing speedometer drive
gear Page 39
-14

Breather installation position Fig. 1
2 -
Torx bolt
Always replace35 Nm (26 ft lb)Self-locking
3 -
Guide sleeve Installed with O-ring and seal for input shaft
Page 30
-20

4 -
Dished washer
Pa
ge 5 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5

34-51


Input shaft, drive pinion, hollow shaft,
shift rods, transmission cover and Torsen
differential cover, removing and installing

1 -
Transmission housing
2 -
Input shaft
Disassembling and assembling Page 35
-1
Adjusting Page 35
-17
Servicing input shaft bearings Page 35
-1
3 -
Shift rod with shift fork for 3rd and 4th
gear
Disassembling and assembling Page 34
-79

Replacing bushings Page 34
-84
4 -
Left stop bolt
40 Nm (30 ft lb)
5 -
Sealing washer
Pa
ge 10 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5

34-53


13 -
Drive pinion with hollow shaft
Disassembling and assembling Page 35
-21

Adjusting Page 39
-34
Servicing drive pinion and hollow shaft
bearings Page 35
-21

14 -
Transmission cover
Removing and installing oil collector tray
Fig. 1

15 -
Torx bolt
22 Nm (16 ft lb)
16 -
Compression spring
17 -
Torsen differential cover Removing and installing with transmission
installed Page 34
-39

Removing and installing Torsen differential
from cover Page 34
-68

Servicing cover Page 34
-68
18 -
Torx bolt
22 Nm (16 ft lb)
Pa
ge 12 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5

34-55

Input shaft ball bearing, multi-function
switch, input shaft, drive pinion, shift
rods, transmission cover and Torsen
differential cover, removing and
installing


Notes:

To remove the above-mentioned components it
is not necessary to remove the differential.
Removal is only necessary when adjustments
have to be performed Page 39
-37
, list of
adjustments

Special tools and equipment

VW309 holding plate
VW353 transmission support
3235 press device
VAG1306 drip tray
VAG1582 taper roller bearing puller

Pa
ge 14 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5

34-58


- Remove cover -A- together with Torsen differential from transmission
cover -B-.
- Remove compression spring from drive pinion.
- Remove transmission cover -B- from transmission housing -C-.

- Remove bolts (arrows) and pull out multi-function switch.
Pa
ge 18 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5

34-65


- Make sure dowel sleeves for transmission cover -A- are installed in
transmission housing -B- (arrows).
- Install transmission cover onto transmission housing.

- Make sure dowel sleeves for cover -A- are installed in transmission
cover -B- (arrows).
- Install compression spring -C-.
- Install Torsen differential cover -A- onto transmission cover -B-.
Pa
ge 25 of 27 Transmission, disassemblin
g and assemblin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.34.5