Torsen Differential, Removing and Installing

5 Speed Automatic 01V

Torsen Differential, removing and installing

Removing
- Remove front exhaust pipes:





- Remove heat shield for drive shaft from cover for torsen differential (arrows).





- Remove drive shaft -1- at transmission and place this on the heat shield -2-.
- Secure drive shaft to bracket for fuel lines using wire (arrow) or support drive shaft using VAG1 383A transmission lift.
- Drain transmission fluid from transfer case.





- Loosen mounting bolts -arrows- for differential and remove.

CAUTION: Remove the differential housing from the transmission slowly and carefully to prevent the Torsen differential from dropping out of the transmission.





- Remove Torsen differential completely in direction of arrow from the back out of output shaft

Installing
Install in reverse order. In addition, the following work steps must be performed:





- Check installation sleeves -arrow A and -arrow B-.
- Position gasket.

Note: Lightly coat sealing surface -D- with petroleum jelly before installing housing in order to avoid gasket slippage.

- Slide cleaned solenoids into cast pocket -1- in intermediate flange.
- Pour 200 ml of gear oil into output housing (like when filling transmission fluid for removed and disassembled transfer case.





- Install Torsen differential in direction of arrow on splines of shaft.
- Check whether the Torsen differential can be turned by hand once in place.
- Position differential housing with installed Spur gears and rear drive flange onto transmission.
- Install mounting bolts for differential housing, tighten by hand and then tighten in crosswise pattern.
- Bolt drive shaft to transmission flange.





- Fill differential with transmission fluid and check.





Tightening Torques