2000 AUDI S4 differential

34-54


Bearing housing, Torsen
differential, end cover, internal
selector mechanism, input
shaft, drive pinion and hollow
shaft, removing and installing
(assembly sequence)

Special tools, testers and auxiliary items
required:

Engine and transmission support VW 540
Drip tray V.A.G 1306
Multi-purpose tool 771/1 with attachments
771/15, 771/37 and stud M8/ M10
Two-arm puller e.g. Kukko 20/10 with 200 mm
long hooks
Mandrel 2064
Clamping sleeve 3116
Thrust piece 3118
Pa
ge 1 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

Drift 3121
Internal puller 3275
Pressing tool 3276
Pa
ge 2 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-55

Thrust plate VW 402
Press tool VW 407
Press tool VW 412
Tube VW 415a
Thrust plate VW 447h
Thrust pad VW 454
Extractor lever VW 681
Extension piece 30-23
Drift sleeve 30-100
Support bridge 30-211A
Press tool 40-21
Depth gauge
Pa
ge 3 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-56

Removing

- Secure transmission on engine and transmission support VW 540.
- Place drip tray V.A.G 1306 underneath and drain transmission oil (2 oil
drain plugs).
- Remove release bearing, clutch release lever and guide sleeve
Page 30
-27
.

- Remove bearing housing (arrow) and pull off.
A - M8/M10 stud
Pa
ge 4 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-57


When pulling off, bearing housing is pressed slightly off end cover by
spring -A-.
- Note position of spring plate -C- when removing bearing housing.

Outer diameter (concave side) towards shims
- Remove shims -B-, note thickness re-determine if necessary Page
34
-85
.

- Pull Torsen differential out of end cover.
Pa
ge 5 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-58


- Pull oil collector out of end cover (arrow) until it moves freely.

- Swing oil collector (arrow) down and guide out through hole in end
cover.
- Remove oil collector.
Pa
ge 6 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-59


- Remove locking bolts -A- for selector shaft from transmission housing.
- Mark installation positions of aluminium bolts and steel bolts; do not
interchange.
- Remove 3 bolts -B- for cover for selector shaft, take off cover.
- Pull out selector shaft.

- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do
this by moving 2 selector plates (arrows).
Pa
ge 7 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5

34-60


- Loosen and unscrew multi-point socket head bolt (arrow -B-) in input
shaft through hole (arrow -A-) in end cover.
- Remove 2 securing bolts (arrow -C-) for end cover for transmission at
supporting plate for needle bearings -arrow D-.
- Take out supporting plate.

- Remove 2 magnets (arrows -A-) and clean.
- Loosen 5 bolts (arrows -B-) for securing end cover for transmission and
remove.
Pa
ge 8 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, removi...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5