AUDI S4 1995 B5 / 1.G 01E Transmission Bearing House And Torsen Differential Workshop Manual

34-54


Bearing housing, Torsen
differential, end cover, internal
selector mechanism, input
shaft, drive pinion and hollow
shaft, removing and installing
(assembly sequence)

Special tools, testers and auxiliary items
required:

Engine and transmission support VW 540
Drip tray V.A.G 1306
Multi-purpose tool 771/1 with attachments
771/15, 771/37 and stud M8/ M10
Two-arm puller e.g. Kukko 20/10 with 200 mm
long hooks
Mandrel 2064
Clamping sleeve 3116
Thrust piece 3118
Pa
ge 1 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

Drift 3121
Internal puller 3275
Pressing tool 3276
Pa
ge 2 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-55

Thrust plate VW 402
Press tool VW 407
Press tool VW 412
Tube VW 415a
Thrust plate VW 447h
Thrust pad VW 454
Extractor lever VW 681
Extension piece 30-23
Drift sleeve 30-100
Support bridge 30-211A
Press tool 40-21
Depth gauge
Pa
ge 3 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-56

Removing

- Secure transmission on engine and transmission support VW 540.
- Place drip tray V.A.G 1306 underneath and drain transmission oil (2 oil
drain plugs).
- Remove release bearing, clutch release lever and guide sleeve
Page 30
-27
.

- Remove bearing housing (arrow) and pull off.
A - M8/M10 stud
Pa
ge 4 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-57


When pulling off, bearing housing is pressed slightly off end cover by
spring -A-.
- Note position of spring plate -C- when removing bearing housing.

Outer diameter (concave side) towards shims
- Remove shims -B-, note thickness re-determine if necessary Page
34
-85
.

- Pull Torsen differential out of end cover.
Pa
ge 5 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-58


- Pull oil collector out of end cover (arrow) until it moves freely.

- Swing oil collector (arrow) down and guide out through hole in end
cover.
- Remove oil collector.
Pa
ge 6 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-59


- Remove locking bolts -A- for selector shaft from transmission housing.
- Mark installation positions of aluminium bolts and steel bolts; do not
interchange.
- Remove 3 bolts -B- for cover for selector shaft, take off cover.
- Pull out selector shaft.

- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do
this by moving 2 selector plates (arrows).
Pa
ge 7 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-60


- Loosen and unscrew multi-point socket head bolt (arrow -B-) in input
shaft through hole (arrow -A-) in end cover.
- Remove 2 securing bolts (arrow -C-) for end cover for transmission at
supporting plate for needle bearings -arrow D-.
- Take out supporting plate.

- Remove 2 magnets (arrows -A-) and clean.
- Loosen 5 bolts (arrows -B-) for securing end cover for transmission and
remove.
Pa
ge 8 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-61


Note:
The internal extractor 3275 grips the circumferential groove of the inner
race (arrow) during the pulling operation. - Pull 2nd inner race for ball bearing for input shaft from input shaft.
A - Washer
- Take off end cover together with end cover/bearing plate gasket.
- Pull dowel sleeves out of bearing plate.

- Pull off 5th speed sliding gear with spring together with 1st inner race -
A- for ball bearing for input shaft.
B - Two arm puller, e.g. Kukko 20/10
- Take off 5th gear synchro-ring.
- Take off circlip for 5th speed gear.
Pa
ge 9 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-62


Note:
Use only hex bolt of tensioning sleeve 3116, length 50 mm. - Pull off 5th speed gear, to do this, block hollow shaft by engaging 2
gears Page 34
-59
.
C - Two arm puller, e.g. Kukko 20/10 with 200 mm long puller arms
- Remove shim -B- for 5th speed gear, note thickness and re-determine
if necessary Page 34
-78
.
- Take off spacer sleeve -A-.

Note:
Do not drive out roll pin, otherwise selector rod bearing will be damaged. - Press out roll pin -A- for selector fork for 5th and 6th gear.
- Pull selector rod on follower together with selector fork for 5th and 6th
gear and locking collar as far as possible away from bearing plate (until
stop is felt).
Pa
ge 10 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5