Servicing cover for Torsen differential, removing and installing Torsen differential — AUDI

Special tools, testers and auxiliary equipment required

Thrust plates VW 401 and VW 402
Press tool VW 407
Press tool VW 412
Tube VW 416 B
Tube VW 421
Guide piece VW 439
Extractor lever VW 681
Tube VW 519
VW 771/15 from multi-purpose tool set VW 771
Drift sleeve 40-21
Tube 2040
Thrust pad 3002
Separating tool Kukko 17/2
Internal puller Kukko 21/4

Gearbox cover
Spring
Front needle roller bearing
Pulling out
=> Fig.
34-81
Installation position
=> Fig.
34-82
Pressing in
=> Fig.
34-83

Torsen differential
Do not dismantle
Press out after removing flange shaft
=> Fig.
34-79
Replace if damaged
Pressing in
=> Fig.
34-83

Rear needle roller bearing
Pulling out
=> Fig.
34-81
Installation position
=> Fig.
34-82
Pressing in
=> Fig.
34-83

Ball bearing
For Torsen differential
Pressing off
=> Fig.
34-79
Pressing on
=> Fig.
34-80

Circlip
Circlip
Remove and install together with flange shaft
=> Fig.
34-78

Ball bearing
For flange shaft
Pressing out
=> Fig.
34-80
Pressing in
=> Fig.
34-81

Cover
For Torsen differential

Circlip
Cap
Removing
=> Fig.
34-78

O-ring
Replace
Grease when installing

Torx bolt - 22 Nm

Oil seal
Pull out with lever VW 681
Driving in
=> Fig.
34-84

Vibration damper
Circlip
Torx bolt - 35 Nm
Self-locking
Replace

Flange shaft
Removing and installing
=> Fig.
34-78

Fig.1
Removing sealing cap

Remove circlip -A-.
Screw M8 bolt into thread of sealing cap -B-.
Pull out sealing cap -8- using bolt.

Fig.2
Removing and installing flange shaft

Open out circlip and pull out flange shaft.
When inserting flange shaft, fit circlip at the same time.
Circlip must be properly seated in the base of the groove

Fig.3
Pressing out Torsen differential

Position thrust pad 3002 directly on Torsen differential through opening (arrow).

Fig.4
Pressing off ball bearing from Torsen differential

A -
Separating device 22 ... 115 mm, e.g. Kukko 17/2

Fig.5
Pressing ball bearing onto Torsen differential

Press the ball bearing on as far as stop.

Fig.6
Pressing out ball bearing for flange shaft

Remove circlip before pressing off.

Fig.7
Pressing in ball bearing for flange shaft

Fit circlip after pressing in bearing.

Fig.8
Pulling out needle roller bearing

A -
Internal puller 22 ... 28 mm, e.g. Kukko 21/4

Both needle roller bearings in Torsen differential are removed with same puller.

Fig.9
Installation position of front needle roller bearing

Dimension a = 32.5 mm

Fig.10
Installation position of rear needle roller bearing

Dimension a = 14 mm

Fig.11
Pressing in needle roller bearing

Both needle roller bearings in Torsen differential are pressed in with same special tool.

Fig.12
Pressing in Torsen differential

Fig.13
Inserting oil seal

Pack space between sealing and dust lips with multi-purpose grease.
Lightly oil outer circumference of seal.
Installation position: 2 mm below surface of cover