Dismantling and assembling differential, all-wheel drive — AUDI

🧭 Before you start

Fits: VW Caddy III (2K, 2004–2015); platform code 2C0

• Special tools named: puller
• Renewed: it if necessary

Don't miss

• When pulling off the tapered roller bearing inner race, ensure that hooks are not bent outwards. Tighten bolt (arrow) further if necessary.
• If necessary, removed sheared-off parts of spring pin from differential cage.

📋 Procedure

1. Clamp internal puller (B) between tapered roller bearing outer race and washer. [Note: Clamp internal puller(B) between tapered roller bearing outer race and washer.After pulling out, check washer for damage, and renew it if necessary.Instead of using the internal puller 46 … 58 mmKukko 21/7, it is also possible to use the internal puller 56 … 70 mmKukko 21/8.] [Note: Observe installation position of washer.Shoulder on inner circumference faces seal in clutch housing.]
2. Place thrust plate40-105 on differential cage.
3. Clamp puller, e.g. Kukko 204/2 in vicinity of flattened sides of differential cage under inner race of tapered roller bearing. [Note: When pulling off the tapered roller bearing inner race, ensure that hooks are not bent outwards. Tighten bolt (arrow) further if necessary.]
4. Set sleeve 3301/3 from assembly tool3301 with notch (arrow) (larger inner diameter) on tapered roller bearing inner race.
5. Support gearbox housing with tube3345 directly below bearing support.

6. First drive spring pin (1) flush into differential pinion pin (2).
7. Set differential under press with spring pin (arrow) facing extension30 - 23.
8. Now press differential pinion pin out. [Note: If necessary, removed sheared-off parts of spring pin from differential cage.]
9. Lubricate one-piece thrust washer with gear oil and install.
10. Install both sun wheels and secure (e.g. with flange shaft).
11. Insert planet pinions offset 180° and pivot into position.
12. Press in differential pinion pin ((arrow A)) to first planet pinion.
13. Place threaded pieces (arrows B) in sun gears.
14. Drive differential pinion pin into final position and secure with spring pin .
15. Drive in new spring pin (arrow) flush to differential cage using a drift (1).

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