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

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Differential, disassembling
and assembling

Special tools and equipment

VW295 needle bearing drift
VW401 thrust plate
VW402 thrust plate
VW407 punch
VW408A punch
VW412 thrust disc
VW442 thrust pad
40-21 sleeve
40-105 thrust piece
2050 thrust plate

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3138 drift
VAG1582 tapered roller bearing puller with
VAG1582/6 attachment
Kukko 44/2 two arm puller
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Notes:

Observe general repair instructions Page 00
-
14
.
Replace both tapered roller bearings together. If
possible use same manufacturer.
Adjustments are required when replacing
components marked with 1) List of
adjustments, Page 39
-149
.
1 -
Cover for final drive1)
2 -
O-ring
Always replaceLubricate with oil before installing
3 -
Final drive housing1)
4 -
Shim S2 Note thicknessList of adjustments Page 39
-149
5 -
Small tapered roller bearing outer race1)
Removing Fig. 1Pressing in Fig. 2
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6 -
Small tapered roller bearing inner race1)
Removing Fig. 3Installing Fig. 4
7 -
Bolt
Always replaceLightly tighten bolts, then tighten diagonally
to correct torque 60 Nm (44 ft lb) + 1/8 turn (45 )Allocation parts catalog
8 -
Differential housing1)
9 -
Ring gear1)
Matched with pinion shaft (in ring gear and
pinion set) Select correct version according to code
letters parts catalog Remove differential housing using mandrel
Fig. 9

Installing on differential housing Fig. 10
10 -
Roll pin
For securing differential bevel gear shaft
for differential bevel gears Drive in flush
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11 -
Large tapered roller bearing inner race1)
Removing Fig. 5Installing Fig. 6
12 -
Large tapered roller bearing outer race1)
Removing Fig. 7Installing Fig. 8
13 -
Shim S1
Note thicknessList of adjustments Page 39
-149
14 -
Threaded piece
15 -
Differential bevel gears, large
Installing Fig. 11Adjusting Fig. 12
16 -
Differential bevel gears, small
Installing Fig. 11
17 -
Differential bevel gear shaft
Drive out using driftCarefully drive in, so that thrust washer is
not damaged Secure with roll pin (item -10-)
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18 -
Shim
Re-determining thickness Fig. 12
19 -
Thrust washer
Check for cracks
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Fig. 1 Removing small tapered roller bearing outer race from
final drive housing
- After removing, check shims for damage.

Fig. 2 Pressing small tapered roller bearing outer race into rear
final drive housing (drive in to stop)
- Using VW295 needle bearing drift, lightly tap outer race into place.
- Drive in until stop is reached as shown in illustration.
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Fig. 3 Removing small tapered roller bearing inner race
A - Two arm puller, e.g. Kukko 44/2
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WARNING!
Wear protective gloves. Fig. 4 Installing small tapered roller bearing inner race
-
Heat bearing to approx. 100 C (212 F), install and press down.

Fig. 5 Removing large tapered roller bearing inner race
- Before installing extractor, position 40-105 thrust piece on differential
housing.
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39-129


WARNING!
Wear protective gloves. Fig. 6 Installing large tapered roller bearing inner race
-
Heat bearing to approx. 100 C (212 F), install and press down.

Fig. 7 Removing large tapered roller bearing outer race from final
drive cover
- After removing, check shims for damage.
Pa
ge 10 of 14 Differential, disassemblin
g and assemblin
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