Repairing a differential gear in an Audi TT is a complex task that requires mechanical knowledge, specialized tools, and a good understanding of the vehicle’s drivetrain. click here for more details on the download manual…..
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Below is a detailed guide to help you understand the components involved and the steps necessary for differential gear repair.
### Components of the Differential System
1. **Differential Housing**: The casing that contains the differential gears and lubricating oil. It is usually mounted between the rear wheels.
2. **Ring Gear**: A large gear attached to the differential housing that receives power from the driveshaft.
3. **Pinion Gear**: A smaller gear that meshes with the ring gear and transfers power from the driveshaft.
4. **Differential Carrier**: The assembly that holds the differential gears and allows them to rotate at different speeds.
5. **Spider Gears**: These are the gears inside the differential that allow for the difference in wheel speed during turns.
6. **Side Gears**: Attached to the axle shafts, these gears mesh with the spider gears.
7. **Bearing**: Supports the differential and reduces friction.
8. **Seals**: Prevent oil leaks from the differential housing.
9. **Gear Oil**: The lubricant that keeps the gears running smoothly.
### Tools Required
– Socket wrench set
– Torque wrench
– Screwdriver set
– Pliers
– Differential oil pump
– Bearing puller
– Gasket scraper
– Clean rags
– Magnetic tray (for holding small parts)
### Step-by-Step Differential Gear Repair
#### 1. Preparation
– **Safety First**: Ensure the vehicle is parked on a flat surface, engage the parking brake, and use wheel chocks.
– **Disconnect the Battery**: Prevent any electrical issues while working on the vehicle.
#### 2. Remove the Rear Wheels
– Loosen the lug nuts with a socket wrench.
– Lift the vehicle using a jack and secure it with jack stands.
– Remove the rear wheels completely.
#### 3. Drain Differential Fluid
– Locate the differential drain plug and remove it. Allow the fluid to completely drain into a pan.
– Replace the drain plug once the fluid has drained.
#### 4. Remove the Differential Assembly
– Disconnect the driveshaft from the differential by removing the bolts securing it.
– Disconnect any electrical connectors (if applicable).
– Remove the bolts securing the differential housing to the vehicle’s subframe.
– Carefully lower the differential assembly and remove it from the vehicle.
#### 5. Disassemble the Differential
– Place the differential on a clean workbench.
– Remove the cover by unscrewing the bolts and carefully prying it off.
– Inspect the gasket. If it’s damaged, you’ll need to replace it.
– Remove the ring gear by unscrewing the bolts.
#### 6. Inspect Components
– Check the ring and pinion gears for wear, pitting, or chips.
– Inspect the spider gears and side gears for damage.
– Check the bearings for smooth rotation and signs of wear.
– look for any metal shavings in the oil, which can indicate severe wear.
#### 7. Replace Damaged Components
– If any components are damaged, replace them with new parts. Be sure to match the gear specifications (ratio, size).
– If bearings are worn, use a bearing puller to remove them and press new ones in place.
#### 8. Reassemble the Differential
– Install the **new or refurbished ring gear** onto the differential carrier.
– Tighten the bolts to specification.
– Reconnect any electrical connectors.
#### 10. Fill the Differential with Oil
– Using a differential oil pump, fill the differential with the appropriate type of gear oil until it reaches the fill plug level.
#### 11. Reinstall Rear Wheels and Lower the Vehicle
– Place the rear wheels back on and tighten the lug nuts.
– Lower the vehicle from the jack stands and remove the wheel chocks.
#### 12. Test Drive
– Reconnect the battery.
– Take the vehicle for a short test drive to ensure that the differential operates smoothly and quietly.
– Check for any leaks under the differential area.
### Conclusion
Repairing a differential gear in an Audi TT can be a challenging task, but with the right tools and knowledge of the components involved, it can be accomplished. Always refer to the vehicle’s service manual for specific torque specifications and procedures. If you are not comfortable performing this repair, it is advisable to seek the assistance of a professional mechanic.
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