VW Passat & Audi A4 1990-2000

Differential Assembly

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Fig. The differential is mounted to the front and rear crossmembers, which are bolted to the vehicle's underbody and the rear subframe

REMOVAL & INSTALLATION
1998-00 Passat Models
  1. Raise and safely support the vehicle.
  2.  
  3. Matchmark the driveshaft CV joint to the differential drive flange and disconnect the driveshaft.
  4.  
  5. Remove the cover plate on the rear final drive assembly.
  6.  
  7. Matchmark and disconnect the rear axles from the differential. Support the axles aside with mechanic's wire.
  8.  
  9. Place a suitable transmission jack underneath, such as Tool No. VAG1383A and adapter Tool No. VAG1359/2, and support the differential.
  10.  
  11. Remove the mounting fasteners from the front mounting bracket, then remove the fasteners from the rear mounting bracket.
  12.  
  13. Carefully lower the differential.
  14.  

To install:

  1. Installation is in reverse order of removal noting the following:
  2.  
  3. Clean the threads of the drive flange with a suitable tap.
  4.  
  5. When installing the driveshaft make sure to align the matchmarks made during disassembly and attach the driveshaft CV joint using new bolts.
  6.  
  7. Observe the following tightening torque specifications:
  8.  
  9. Differential mount, front: 30 ft. lbs. (40 Nm)
  10.  
  11. Differential mount, rear: 41 ft. lbs. (55 Nm)
  12.  
  13. Differential cover plate: 41 ft. lbs. (55 Nm)
  14.  
  15. Driveshaft-to-differential: 41 ft. lbs. (55 Nm)
  16.  
  17. CV joint-to-differential: 30 ft. lbs. (40 Nm)
  18.  
  19. Check and top off the differential oil as necessary.
  20.  

A4 Models
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear portion of the exhaust system.
  4.  
  5. Remove the heat shield over the drive shaft.
  6.  
  7. Matchmark the driveshaft CV joint to the differential drive flange and disconnect the driveshaft. Support the driveshaft via the parking brake cable using mechanic's wire.
  8.  
  9. Matchmark and disconnect the rear axles from the differential. Support the axles aside with mechanic's wire.
  10.  
  11. Place a suitable transmission jack underneath, such as Tool No. VAG1383A and adapter Tool No. VAG1359/2, and support the differential.
  12.  
  13. Remove the mounting fasteners from the front mounting bracket, then remove the fasteners securing the rear mounting bracket to the differential.
  14.  
  15. Carefully lower the differential.
  16.  

To install:

  1. Installation is in reverse order of removal noting the following:
  2.  
  3. Clean the threads of the drive flange with a suitable tap.
  4.  
  5. When installing the driveshaft make sure to align the matchmarks made during disassembly and attach the driveshaft CV joint using new bolts.
  6.  
  7. Observe the following tightening torque specifications:
  8.  
  9. Front crossmember to body M8: 17 ft. lbs. (23 Nm)
  10.  
  11. Front crossmember to body M10: 30 ft. lbs. (40 Nm)
  12.  
  13. Front crossmember to differential M10: 30 ft. lbs. (40 Nm)
  14.  
  15. Rear crossmember to subframe M10: 37 ft. lbs. (50 Nm)
  16.  
  17. Rear crossmember to differential M10: 41 ft. lbs. (55 Nm)
  18.  
  19. Driveshaft-to-differential: 41 ft. lbs. (55 Nm)
  20.  
  21. CV joint-to-differential: 30 ft. lbs. (40 Nm)
  22.  
  23. Check and top off the differential oil as necessary.
  24.  

 
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