Dismantling and assembling differential, four-wheel drive — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012), Audi TT Mk2 (8J, 2006–2014)

• Special tools named: puller
• Renewed: if necessary

Don't miss

• After pulling out, check shim for damage and renew if necessary.
• When pulling off the inner race ensure that the hooks do not bend outwards, if necessary tighten bolt (arrow).
• Remove any sheared off parts of the spring pin from the differential cage and differential pinion pin.

📋 Procedure

1. Clamp internal puller(B) firmly between tapered roller bearing outer race and shim. [Note: After pulling out, check shim for damage and renew if necessary.] [Note: Note installation position of shim .Shoulder on inside diameter faces oil seal in clutch housing.]
2. Fit thrust plate40-105 onto differential cage.
3. Clamp jaws of puller (e.g. Kukko 204/2) under tapered roller bearing inner race on flat surfaces of differential cage. [Note: When pulling off the inner race ensure that the hooks do not bend outwards, if necessary tighten bolt (arrow).]
4. ⚠ Wear protective gloves. — Heat tapered roller bearing inner race to approx. 100°C before pressing on.
5. ⚠ Wear protective gloves. — Heat tapered roller bearing inner race to approx. 100°C before pressing on.

6. Fit sleeve 3301/3 of assembly device3301 onto tapered roller bearing inner race with recess (arrow) (larger inner diameter) facing downwards.
7. Support gearbox housing with tube 3345 directly below bearing mounting.
8. First drive spring pin (1) into differential pinion pin (2) so it is flush.
9. Fit differential under press, with spring pin (arrow) facing towards extension30 - 23.
10. Now press out differential pinion pin. [Note: Remove any sheared off parts of the spring pin from the differential cage and differential pinion pin.]
11. Lubricate one-piece thrust washer with gear oil and install.
12. Install both sun wheels and secure (e.g. with flange shaft).
13. Fit planet pinions (180° apart) and pivot into position.
14. Push differential pinion pin (arrow A) in as far as first planet pinion.
15. Fit threaded pieces (arrows B) in sun wheels.
16. Drive differential pinion pin into final position and secure with spring pin .
17. Use a punch (1) to drive new spring pin (arrow) in flush with differential cage.

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