1996 AUDI A4 01V Transmission Rear Differential Assembly Workshop Manual

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Fig. 1 Driving small tapered roller bearing outer race out of
housing
- Check adjustment shims for damage after removing.

Fig. 2 Pressing tapered roller bearing outer race into housing
- Install outer race with VW295 needle bearing drift by tapping lightly
using hammer.
- Then drive in to stop, as shown in illustration.
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Fig. 3 Pulling off small tapered roller bearing inner race
A - Kukko 44/2 two-arm puller
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WARNING!
Wear protective gloves! Fig. 4 Pressing on small tapered roller bearing inner race
-
Heat inner race to approx. 100 C ,position and press on.

Fig. 5 Pulling off large tapered roller bearing inner race
- Before installing removal tool, set 40-105 thrust piece onto differential
housing.
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WARNING!
Wear protective gloves! Fig. 6 Pressing on large tapered roller bearing inner race
-
Heat inner race to approx. 100 C ,position and press on.

Fig. 7 Driving large tapered roller bearing outer race out of cover
- Check adjustment shims for damage after removing.
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Fig. 8 Pressing large tapered roller bearing outer race into cover

Fig. 9 Driving out ring gear from housing
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WARNING!
Wear protective gloves! Fig. 10 Installing ring gear
- When installing ring gear, guide with centering pins -A- (self-made).
-
Heat ring gear to approx. 100 C and position.

Fig. 11 Installing small differential bevel gears
- If the large differential bevel gears were replaced, adjustment shims
must be re-determined Fig. 12
.
- Insert large differential bevel gears with determined adjustment shims.
-
Insert small differential bevel gears at 180 from their final position
and rotate into place (arrow). - Install thrust washers and locate.
- Install threaded pieces.
- Drive in differential bevel gear shaft to final position and secure.
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Note:
Do not rearrange differential bevel gears and thrust washers again!
Parts-catalog Fig. 12 Adjusting differential bevel gears
- Install large differential bevel gears with the thinnest shims (0.5 mm).
-
Insert small differential bevel gears 180 from final position together
with thrust washers. - Drive in shaft for differential bevel gears.
- Press the small differential bevel gears toward the outside.
- Push large differential bevel gears in direction of arrow and check play.
- Determine the largest possible shim that can still be installed for the
large differential bevel gears on each side.

Adjustment shims should be the same thickness on both sides.
- Determine adjustment shims according to table. Part numbers
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Available adjustment shims:

Shim thickness (mm)
0.50 0.70 0.90
0.60 0.80 1.00

Note:

The adjustment is also correct when no more play can be felt, but the
differential bevel gears can just barely be rotated (arrow).
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