Dismantling and assembling differential: Audi A4 B5

🧭 Before you start

Fits: Audi A4 B5 (8D)

• Special tools named: puller
• Also covered elsewhere: Electronic parts catalogue

Don't miss

• Shim thicknesses must be re-determined if sun wheels have been renewed .
• Ensure that bevel gears and thrust washers are not interchanged from this point onwards.
• The adjustment is also correct if no further play is perceptible, although it is still just possible to rotate the differential bevel gears (arrow).

📋 Procedure

1. After removing, check shims for damage.
2. ⚠ Wear protective gloves. — Heat inner race to approx. 100 °C, fit in position and press home.
3. Before setting up the puller, place thrust plate40 - 105 on differential cage.
4. ⚠ Wear protective gloves. — Heat inner race to approx. 100 °C, fit in position and press home.
5. After removing, check shims for damage.

6. ⚠ Wear protective gloves. — When fitting crown wheel, use centralising pins (A) (shop-made tool) to locate.
7. Heat crown wheel to approx. 100°C and install.
8. Allow to cool slightly before screwing in new securing bolts.
9. Then tighten bolts in stages and in diagonal sequence until crown wheel makes full contact with differential cage.
10. Then tighten bolts to specified torque .
11. Shim thicknesses must be re-determined if sun wheels have been renewed .
12. Install sun wheels with correct shims (as measured).
13. Insert planet pinions (spaced 180° apart) and pivot into position (arrow).
14. Fit and align thrust washers.
15. Insert threaded pieces.
16. Drive differential pinion pin into final position and secure.
17. Insert sun wheels with thinnest shims (0.5 mm).
18. Insert planet pinions with thrust washers (spaced at 180°). [Note: Ensure that bevel gears and thrust washers are not interchanged from this point onwards.]
19. Drive in differential pinion pin.
20. Press planet pinions outwards.
21. Press sun wheels in direction of (arrows) and check the amount of play.
22. Determine the thickest shim that can still just be fitted for the sun wheels on each side.
23. Select required shims from table. For part numbers, refer to Electronic parts catalogue. [Note: The adjustment is also correct if no further play is perceptible, although it is still just possible to rotate the differential bevel gears (arrow).]

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