Rear Final Drive Audi A4 B7

The 01R rear final drive in the Audi A4 2001 > is assigned to the following transmissions

1. 5-Speed Manual Transmission 01A, AWD
2. 6-speed Manual Transmission 01E, AWD
3. 6-speed Manual Transmission 02X, AWD
4. 6-speed Manual Transmission 0A3, AWD

1. Automatic Transmission 01V, AWD
2. Automatic Transmission 09L, AWD

Allocation. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD , Technical data

Scheme 1200

Location on final drive

Code letters and date of manufacture (arrow 1)

Final drive 01R (arrow 2)

Scheme 1201

Final drive 01R (arrow 2)

Scheme 1202

Code letters and manufacturing data for the final drive

Additional data is production-related

Allocation of mechanical units: 5-speed Manual Transmission 01A AWD

Allocation of mechanical units: 6-speed Manual Transmission 01E, AWD

Allocation of mechanical units: 6-speed Manual Transmission 02X, AWD

Allocation of mechanical units: 6-speed Manual Transmission 0A3, AWD

Allocation of mechanical units: Automatic Transmission 01V FWD and AWD

Allocation of mechanical units: Automatic Gearbox 09L, AWD

Scheme 1203

1. Illustrated with the 6-speed manual transmission 01E all wheel drive

Designation

1 - Engine

2 - Clutch

3 - Manual transmission

4 - Input shaft

5 - Front differential

6 - Front drive pinion (output shaft)

7 - Hollow shaft

8 - Torsen differential

9 - Drive shaft

10 - Rear drive pinion

11 - Rear differential

Arrows in direction of travel

Ratio

Arrows in direction of travel

Repair instructions

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the article, are summarized here. They apply to this article.

Transmission

1. When replacing rear final drive the oil level in rear final drive must be checked and, if necessary, corrected. Refer to «Gear oil level in rear final drive, checking»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .
2. Capacities and specifications. Refer to «Allocation of mechanical units: 5-speed Manual Transmission 01A AWD»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__allocation-of-mechanical-units-5-speed-manual) .
3. When assembling mounting brackets as well as waxed components clean contact surfaces. The contact surfaces must be free of wax and grease.

Gaskets, sealing rings

1. Replace O-rings.
2. Radial shaft oil seals.

Before installing

Scheme 1204

Lightly oil outer circumference and pack space between sealing lips -arrow- half-full with sealing grease G 052 128 A1.

After installation

Check gear oil in rear final drive; if necessary top off to lower edge of oil filler hole, specification. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD .

Locking elements

1. Replace circlips.
2. Do not over-stretch circlips.
3. Circlips must be properly seated in the base of the groove.

Scheme 1205

1. Replace spring pins.

Installation position: Slot longitudinal to line of force.

Nuts, bolts

1. Nuts and bolts which secure covers and housings should be loosened and tightened diagonally.
2. Parts which are particularly sensitive must not be tilted; loosen or tighten diagonally in stages.
3. Tightening torques stated apply to non-oiled nuts and bolts.
4. Replace self-locking bolts and nuts.

1. Make sure with all screw connections that contact surfaces as well as bolts and nuts are only waxed after assembly, if necessary.

Bearings

1. Attach needle bearing with the written side (greater plate thickness) to the installing tool.
2. Install new taper roller bearings in delivery condition and do not oil.
3. Always replace taper roller bearings on one shaft together and use new bearings from a single manufacturer.
4. Heat inner races to approx. 100°C before installing.

1. Do not interchange outer or inner races of bearings of the same size. The bearings are paired.

Adjustment shims

1. Check thickness of shims by measuring at several points with a micrometer. Different tolerances make it possible to obtain exact shim thickness required.
2. Check for burrs and damage.
3. Install only adjustment shims which are in perfect condition.

Drive shaft, servicing

Note. General repair instructions. Refer to Repair instructions . Drive shaft may be bent without force up to stop of the central constant velocity joint. Further bending may cause damage to the joint or to the boots. Only store and transport drive shaft extended. No repair work can be carried out on the drive shaft with the exception of removing, installing and adjusting. If the drive shaft is only detached at the transmission or from rear final drive then the drive shaft is to be tied-up at the constant velocity joint. The drive shaft may also be bent without force up to the stop of the central constant velocity joint, if necessary. Prior to removal mark the position of all parts in relation to each other. Reinstall in the same positions otherwise the imbalance will be excessive; the bearings could be damaged and humming noises may occur. After removing the drive shaft from the rear final drive, a thick washer that may be located between the shim and the hexagon socket head bolt must not be reinstalled. If complaints are received (noises, vibrations), it is essential to check the radial run-out to drive flange at the rear final drive. A correct adjustment may repair the problem. Refer to Drive shaft flange, measuring and marking radial run-out .

Scheme 1206

1 - Rear final drive

2 - Drive shaft

1. Removing and installing. Refer to «Drive shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-removing-and-installing) .

3 - Gasket

1. Replace
2. Detach protective foil and stick self-adhesive side of the gasket onto flange shaft
3. Degrease flange shaft

4 - Shim

5 - Hex socket-head bolt - 55 Nm

1. Self-locking
2. Replace
3. The tapped holes for the bolts in the flange shaft must always be cleaned (e.g. with a thread tap)

6 - Combi bolt - 23 Nm

7 - Transmission

Drive shaft, removing and installing

Special tools, testers and auxiliary equipment required

Scheme 1207

1. Assembly tool 3139

Scheme 1208

1. Pressing lever 80-200
2. Bolt M8 x 30 (2x)

Special tools, testers and auxiliary items required

Scheme 1209

1. Engine/transmission jack V.A.G 1383 A with universal transmission mounting V.A.G 1359/2

Removing

1. See notes. Refer to «Drive shaft, servicing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)
2. Remove rear section of exhaust system as from clamp(s)

Refer to

1. 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
2. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
3. 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
4. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
5. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
6. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Removing and installing exhaust-system components

Scheme 1210

1. Use press lever - RMV outside mirror 80-200 to pry off rear attachments -A- of heat shield for drive shaft.
2. Remove securing bolts -B- for center bearing.

Note. When removing the securing bolts support the drive shaft by hand. Do not bend drive shaft. Refer to Drive shaft, servicing .

1. Remove heat shield. Continue supporting drive shaft.
2. Screw in securing bolts for center bearing again hand-tight.

Scheme 1211

1. Remove heat shield for drive shaft off transmission -arrows-.

Scheme 1212

1. Check for a factory marking (colored dot) on drive shaft and on drive shaft flange on final drive at the rear. If no colored dot is present, mark the position of the drive shaft flange -arrow A- relative to the rear final drive -arrow B- with a colored dot.

Scheme 1213

1. Engage alignment fixture-4W dr. shaft 3139 and tighten plastic nuts.

Note. Never install assembly appliance onto balance plates.

Scheme 1214

1. Remove securing bolts -arrows- for the center bearing.

Scheme 1215

1. Screw in bolt -3- M10 x 100 into rear final drive.
2. To loosen bolts -1- of the rear and front drive shaft, counterhold with an assembly lever -2-.
3. Remove securing bolts at the front constant velocity joint, detach the drive shaft and support it using engine/transmission jack V.A.G 1383 A.
4. Remove securing bolts at rear constant velocity joint and detach drive shaft.

Note. Only transport and store drive shaft when extended.

Installing

Installation is carried out in reverse order. Note the following

Note. To avoid imbalance, the flanges of the drive shaft -arrow A- and of the rear final drive -arrow B- must be installed so that the factory color markings or the markings made subsequently are in line. If a new drive shaft is installed and if the factory color marking on the flange of the rear final drive is no longer visible, the radial run-out on the drive shaft flange must be measured. Refer to Drive shaft flange, measuring and marking radial run-out and the color marking on the drive shaft placed in line with the new marking on the flange. Replace gaskets on flange shafts (detach protective foil and stick gasket onto flange shaft). Remove the old and dry high-temperature grease from the constant velocity joints and the flanges for the drive shaft. Replace with the exact same quantity of new high-temperature grease G 000 633. Note the installation position of the drive shaft: The central constant velocity joint is located behind the center bearing facing toward the rear final drive. After removing the drive shaft from the rear final drive, a thick washer that may be located between the shim and the bolt head must not be reinstalled. It is essential that the locking fluid remaining in the threads in the flange shafts on the transmission and rear final drive is cleaned out after removing the drive shaft. Otherwise there is a danger that the new bolts will seize when they are screwed in and then shear if they have to removed later. The threaded holes can be cleaned with a thread tap. Replace drive shaft bolts (self-locking).

1. Install drive shaft and attach bolts for constant velocity joint.

1. Screw in securing bolts -arrows- for center bearing hand-tight.

1. Screw in bolt -3- M10 x 100 into rear final drive.
2. To tighten bolts -1- of the rear and front drive shaft, counterhold with an assembly lever -2-.

1. Remove assembly device 3139
2. Remove securing bolts -arrows- for the center bearing. The drive shaft must be supported manually by a second mechanic.

Note. When removing the securing bolts support the drive shaft by hand. Refer to Drive shaft, servicing .

Scheme 1216

1. Install heat shield -2-. Continue supporting drive shaft.
2. Screw in securing bolts -4- for left and right center bearing several turns.
3. Secure heat shield -2- on right and left at the center bearing -3- using bolts -1- (M8x30).

Note. When tightening the combination bolt -4- make sure that the center plug -arrow A- is located at the securing bore -arrow B-.

Scheme 1217

1. Tighten securing bolts -2- for the center bearing.
2. Install rear securing clips for the heat shield.
3. Remove bolts -1
4. Install exhaust system and align stress-free

Refer to

1. 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
2. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
3. 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
4. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
5. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
6. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Removing and installing exhaust-system components

Tightening torques

Drive shaft flange, measuring and marking radial run-out

Special tools, testers and auxiliary equipment required

Scheme 1218

1. Universal dial indicator bracket VW 387
2. Dial indicator
3. Bolt M10 x 85

Note. The radial run-out must always be measured when the drive shaft flange on the rear final drive has been removed. Affix a new colored dot and remove the old color marking. If a new drive shaft is installed and if the marking on the flange shaft of the rear final drive is no longer visible, the position of maximum radial run-out must be determined and marked by a colored dot. The colored dot on the drive shaft is positioned opposite the above colored dot. Refer to Installing . The radial run-out can be measured when rear final drive is installed but the drive shaft must be disconnected at rear final drive. See notes. Refer to Drive shaft, servicing

Scheme 1219

1. Secure universal dial indicator holder VW 387 with dial indicator at rear final drive.
2. Position dial indicator on ground diameter in drive shaft flange -arrow- and set to "0" with 1 mm preload.
3. Rotate differential by turning the two rear wheels (left and right-hand flange shafts) simultaneously in one direction until the drive shaft flange has undergone one complete revolution.
4. Mark the position of greatest radial run-out on flange exterior by a colored dot (equates to greatest distance from rotational axis).

1. Remove old marking from drive shaft flange.
2. Install drive shaft. Refer to «Drive shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-removing-and-installing) .

Special tools, testers and auxiliary equipment required

Scheme 1220

1. Drip tray V.A.G 1306

1. Place drip tray V.A.G 1306 underneath.

Scheme 1221

1. Remove screw plug -1- to gear oil control.

The oil level is correct when rear final drive is filled to lower edge of filler hole.

1. Top off with gear oil, if necessary

Specification. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD .

1. Install screw plug.

Tightening torque

Flange shaft oil seals, replacing

Special tools, testers and auxiliary equipment required

Scheme 1222

1. Driver 2062

1. Drip tray V.A.G 1306

1. Observe general repair instructions. Refer to «Repair instructions»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)

1. Rear final drive installed

Note. The illustration shows the left-hand side of the rear final drive. The procedure for removing and installing the joint flange and sealing ring on the right-hand side is identical.

Removing

Scheme 1223

1. Remove heat shields from final drive -arrows-.
2. Disconnect drive axle.

Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle

1. Place drip tray underneath to collect oil.

Scheme 1224

1. Remove securing bolt for flange shaft, then screw two bolts into the flange and counterhold the flange shaft using the assembly lever.
2. Pull out flange shaft.

Scheme 1225

1. Pry out flange shaft oil seals using a suitable lever.

Installing

Installation is carried out in reverse order. Note the following

1. Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.
2. Lightly oil outer circumference of seal.

Scheme 1226

1. Drive new seal in onto stop, for this purpose do not cant seal.
2. Insert flange shaft.
3. Fasten flange shaft with cone head bolt.
4. Top off gear oil in rear final drive and check oil level. Refer to «Gear oil level in rear final drive, checking»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

1. Attach drive axles.

Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle

1. Attach heat shields to final drive -arrows-.

Tightening torques

Scheme 1227

The following special tools and testing devices are required

1. V.A.G 1383A Engine/transmission jack with universal mounting V.A.G 1359/2
2. 3028 - Retainer
3. VW 391 -Puller
4. VW 771 - Slide hammer-complete set

1. VW 771/37 Additional part for VW 771
2. 3026 - Mandrel

Scheme 1228

1. Drive pinion 3143
2. Rear final drive installed

1. Observe general repair instructions. Refer to «Repair instructions»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)

1. Remove rear section of exhaust system as from clamp(s)

Refer to

1. 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
2. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
3. 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
4. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
5. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
6. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Removing and installing exhaust-system components

Scheme 1229

1. Check whether there is a factory marking (paint dot) on drive shaft. If you do not find one, mark the position of the constant velocity joint -arrow A- relative to the rear final drive -arrow B-with a colored dot
2. Disconnect drive shaft from rear final drive and tie it up to exhaust system brackets. Refer to «Drive shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-removing-and-installing) .
3. Place engine/transmission jack V.A.G 1383 A with universal transmission mounting 1359/2 under final drive and secure final drive.

Scheme 1230

1. Remove securing bolts -arrows- of left final drive support.
2. Carefully lower final drive until flange is freely accessible.
3. Color-mark the position of the securing nut for the drive pinion.

Scheme 1231

1. Distance of flange to drive pinion =

Dimension a

1. Distance of flange to securing nut for the drive pinion =

Dimension b

1. Note calculated dimensions
2. Count turns when unscrewing the securing nut and make a note of them.

Note. Illustrations show the final drive removed for the following procedure.

Scheme 1232

1. Install support tool 3028 and remove drive pinion nut.
2. Place drip tray underneath to collect oil.

Scheme 1233

1. Detach flange with removal tool VW 391.

A - Screw in two hex bolts M8 x 30 into flange.

Scheme 1234

1. Remove sealing ring.

Installation is carried out in reverse order. Note the following

Scheme 1235

1. Replace O-ring between drive pinion bearing and flange.
2. Lightly oil O-ring before installing.
3. Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.
4. Lightly oil outer circumference of seal.

Scheme 1236

1. Drive in seal for drive shaft flange onto stop with drift 3026.

Scheme 1237

1. Drive shaft flange onto drive pinion until securing nut can be mounted.

Note. Use the old hex nut to reattach the flange to the drive pinion. Otherwise the original installed position will not be relocated.

1. Clean drive pinion nut and threads on drive pinion of oil and grease residues. Thinly coat threads with locking fluid D 000 600.

Note. The number of turns when reattaching must be the same as during unscrewing.

Scheme 1238

Perform control measurement - check dimension "a" and dimension "b". Refer to Calculate dimension "a" and dimension "b" onward.

Note. O-ring -1- must be installed when measuring. The hex nut must be returned to exactly the marked position. Maximum permissible deviation from original measurements: ± 0.3 mm.

Scheme 1239

1. Lock hex nut.
2. Move final drive back to installation position.

1. Screw final drive to front mounting bracket -arrows-.
2. Top off gear oil in rear final drive and check oil level. Refer to «Gear oil level in rear final drive, checking»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .
3. If there was a factory marking at the drive shaft determine now the radial run-out at the flange/drive shaft. Refer to «Drive shaft flange, measuring and marking radial run-out»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-flange-measuring-and-marking) . Attach drive shaft in such a way that the color coding at the drive shaft are aligned with new marking at flange.
4. If the position of the drive shaft relative to the flange/drive shaft were marked before removal the drive shaft must be reattached at same position. Refer to «Drive shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-removing-and-installing) .

Observe installation instructions. Refer to Drive shaft, servicing

1. Replace seal on drive shaft flange and tighten drive shaft to torque. Refer to «Drive shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-removing-and-installing) .
2. Stress-free alignment of exhaust system

Refer to

1. 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
2. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
3. 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
4. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
5. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
6. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Removing and installing exhaust-system components

Tightening torques

Special tools, testers and auxiliary equipment required

1. Engine/transmission jack V.A.G 1383 A with universal transmission mounting V.A.G 1359/2

Removing

1. Remove rear section of exhaust system as from clamp(s)

Refer to

1. 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
2. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
3. 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
4. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
5. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
6. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Removing and installing exhaust-system components

1. Check whether there is a factory marking (paint dot) on drive shaft. If you do not find one, mark position of the drive shaft flange -arrow A- relative to rear final drive -arrow B- with a colored dot.
2. Remove drive shaft from rear final drive. Refer to «Drive shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-removing-and-installing)

Scheme 1240

1. Tie drive shaft to exhaust system bracket using a wire.
2. Remove heat shields for drive axles at final drive.
3. Remove drive axles from left and right from the flanges of the rear final drive.

Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle

Scheme 1241

1. Place engine/transmission jack V.A.G 1383 A with universal transmission mounting 1359/2 under rear final drive and secure rear final drive.

1. Remove securing bolts of mounting bracket of rear final drive -arrows-.

Scheme 1242

1. Remove nuts -arrows- from left and right of cross piece.
2. Pull bolts out of subframe as far as possible.

Note. The bolts remain in the subframe.

1. Slightly lower rear section of final drive.
2. Move drive axles clear toward top.
3. Lower rear section of final drive.

Scheme 1243

1. If rear final drive is replaced then remove rear cross piece -arrows-.

Installing

Installation is carried out in reverse order. Note the following

Note. Always replace self-locking nuts. It is essential that the residues of locking fluid are cleaned out from the threaded holes in flange shaft on the rear final drive after removing the drive shaft. Otherwise there is a danger that the new bolts will seize and then shear when removing them again. The threaded holes can be cleaned with a thread tap. Replace drive shaft bolts (self-locking). Replace gaskets on flange shaft (detach protective foil and stick gasket onto flange shaft). To prevent imbalance, the flanges must be installed so that the paint markings align -arrows A and B-. Install drive shaft. Refer to Installing .

1. When lifting rear final drive, position drive axle onto flange shaft.
2. Lift final drive past the right-hand drive axle until installation position.

Note. All components must move freely.

Scheme 1244

1. Push rear final drive at left-hand drive axle upward -arrows A-.
2. While doing so push constant velocity joint of the drive axle outward until limit stop -arrow B- and lower toward flange shaft -arrow C-.

1. Remove securing bolts of mounting bracket of rear final drive -arrows-.
2. Push bolts in subframe into cross piece until limit stop.

1. Secure nuts on left and right at cross piece -arrows-.

Observe installation instructions. Refer to Drive shaft, servicing

1. Replace seal on drive shaft flange and tighten drive shaft to torque. Refer to «Drive shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-removing-and-installing) .
2. Attach drive axles.

Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle

1. Top off gear oil in rear final drive and check oil level. Refer to «Gear oil level in rear final drive, checking»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .
2. Install exhaust system and align stress-free

Refer to

1. 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
2. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
3. 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
4. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
5. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
6. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Removing and installing exhaust-system components

Tightening torques

Special tools, testers and auxiliary equipment required

Scheme 1245

1. Holding fixture VW 540

Scheme 1246

Scheme 1247

1 - Final drive housing

2 - Spacer sleeve

1. Replace

3 - Flange for drive shaft

1. Removing and installing. Refer to «Drive pinion, removing and installing and disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)

4 - Pinion shaft

1. Is mated with ring gear, replace together as a set
2. Removing and installing. Refer to «Drive pinion, removing and installing and disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)

5 - Final drive cover

6 - Differential

1. Removing and installing. Refer to «Differential, removing and installing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)
2. Disassembling and assembling. Refer to «Differential, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)

7 - Ring gear

1. Paired with pinion shaft (final drive set)
2. Removing and installing. Refer to «Differential, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

Scheme 1248

1. General repair instructions. Refer to «Repair instructions»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .
2. Adjustments are required when replacing components marked 1). Refer to «Adjustment overview»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__adjustment-overview) .

Secure final drive on a repair stand. Refer to Rear final drive, attaching to assembly bracket .

1 - Vent sleeve

1. With rubber valve
2. Installation position. see scheme 67

2 - Final drive housing 1)

1. Removing and installing drive pinion. Refer to «Drive pinion, removing and installing and disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

3 - Outer race for large taper roller bearing 1)

1. Removing and installing. Refer to «Differential, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

4 - Shim "S1"

1. Note thickness
2. Adjustment overview. Refer to «Adjustment overview»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__adjustment-overview) .

5 - Cover for final drive 1)

1. With O-ring
2. Replace O-ring
3. Insert O-ring with oil

6 - TORX-screw - 25 Nm

7 - Seal, right

1. Replacing. Refer to «Flange shaft oil seals, replacing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

8 - Hex socket-head bolt - 25 Nm

9 - Flange shaft, right

1. Removing and installing. (Scheme 1252)

10 - Oil filler plug - 35 Nm

1. Checking gear oil level in rear final drive. Refer to «Gear oil level in rear final drive, checking»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)

11 - Differential with ring gear 1)

1. Disassembling and assembling. Refer to «Differential, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)

12 - Oil drain plug, 35 Nm

13 - Socket

1. Holds solenoid in position
2. Drive in onto stop

14 - Solenoid

15 - Outer race for small taper roller bearing 1)

1. Removing and installing. Refer to «Differential, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

16 - Shim "S2"

1. Note thickness
2. Adjustment overview. Refer to «Adjustment overview»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__adjustment-overview)

17 - Seal, left

1. Replacing. Refer to «Flange shaft oil seals, replacing»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

18 - Flange shaft, left

1. Removing and installing. (Scheme 1252)

19 - Hex socket-head bolt - 25 Nm

20 - Cap

1. Installing. see scheme 66

Scheme 1249

Scheme 1250

Scheme 1251

Scheme 1252

The vent sleeve must protrude from the housing by 13 mm (dimension -a-) after being pressed in.

The slot in rubber valve is located longitudinally in direction of travel.

Removal

1. Rear final drive removed

Special tools, testers and auxiliary equipment required

1. Drip tray V.A.G 1306

1. Clamp complete rear final drive into assembly bracket VW 540. Refer to «Rear final drive, attaching to assembly bracket»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .
2. Place drip tray underneath to collect oil.
3. Drain gear oil.

1. Remove left and right-hand flange shafts.

1. To loosen the securing bolt, screw two bolts into flange shaft and counter-hold with a lever.
2. Mark flange shafts (left and right) and pull out.
3. Remove securing bolts from cover for final drive.
4. Take cover for final drive off axle housing and remove differential.

Installation is in reverse order.

1. Insert differential.
2. Replace O-ring for cover for final drive and oil when installing.
3. Install cover for final drive onto axle housing and using diagonal sequence tighten to 25 Nm.
4. Fill space between sealing lip and dust lip with a thin layer of sealing grease G052 128 A1.

1. Insert flange shafts and tighten to 25 Nm.
2. Top off gear oil in rear final drive and check oil level. Refer to «Gear oil level in rear final drive, checking»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

Scheme 1253

The following special tools and testing devices are required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 407
4. Thrust disc VW 412

1. Needle bearing drift VW 295
2. Punch VW 408 A

Scheme 1254

1. Thrust pad VW 442
2. Sleeve 40-21
3. Thrust piece 40-105
4. Thrust plate 2050

1. Drift 3138
2. Two-arm puller Kukko 44/2

Scheme 1255

1. Taper roller bearing extractor V.A.G 1582

1. V.A.G 1582/6

Note. General repair instructions. Refer to Repair instructions . Secure final drive on a repair stand. Refer to Secure complete rear final drive on a repair stand with bracket VW 540 . Replace both taper roller bearings together. When replacing the parts marked with 1) adjustment work is required. Refer to Adjustment overview .

1 - Cover for final drive 1)

2 - O-ring

1. Replace
2. Insert with oil

3 - Final drive housing 1)

4 - Shim "S1"

1. Note thickness
2. Adjustment overview. Refer to «Adjustment overview»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__adjustment-overview) .

5 - Outer race for small taper roller bearing 1)

1. Tapping out. (Scheme 1259)
2. Pressing in. (Scheme 1260)

6 - Inner race for small taper roller bearing 1)

1. Pulling off. (Scheme 1261)
2. Pressing on. (Scheme 1262)

7 - Bolt - 60 Nm plus an additional45°1/4 turn

1. Replace
2. Allocation

1. Lightly tighten bolts then tighten diagonally to specified torque.

8 - Differential housing 1)

9 - Ring gear 1)

1. Paired with pinion shaft (final drive set)
2. Allocation based on transmission code letters

1. Drive off housing with a drift. (Scheme 1267)
2. Install to differential housing. (Scheme 1268)

10 - Spring pin

1. For securing shaft for bevel gears
2. Drive in flush

11 - Inner race for large taper roller bearing 1)

1. Pulling off. (Scheme 1263)
2. Pressing on. (Scheme 1264)

12 - Outer race for large taper roller bearing 1)

1. Tapping out. (Scheme 1265)
2. Pressing in. (Scheme 1266)

13 - Shim "S2"

1. Note thickness
2. Adjustment overview. Refer to «Adjustment overview»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__adjustment-overview) .

14 - Threaded piece

15 - Large bevel gear

1. Installing. (Scheme 1269)
2. Adjusting. (Scheme 1270)

16 - Small bevel gear

1. Installing. (Scheme 1269)

17 - Shaft for planet wheels

1. Drive out with drift

18 - Adjustment shim

1. Redefine thickness. (Scheme 1270)

19 - Thrust washer

1. Check for cracks

Scheme 1256

1. After removing check shims for damage.

Scheme 1257

Scheme 1258

A - Two arm puller, e.g. Kukko 44/2

Scheme 1259

1. Heat inner race to approx. 100°C, position and push to final position.

Scheme 1260

1. Install thrust plate 40-105 onto differential housing before installing puller.

Scheme 1261

1. Heat inner race to approx. 100°C, position and push to final position.

Scheme 1262

1. After removing check shims for damage.

Scheme 1263

Scheme 1264

Scheme 1265

1. Locate ring gear guide with centering pins -A- (self-produced) when mounting.
2. Heat ring gear to approx. 100°C and position.

Scheme 1266

1. If large bevel gears have been replaced, measure and select new shims. (Scheme 1270)
2. Insert large bevel gears with recalibrated shims.
3. Insert small bevel gears spaced 180° apart, and then rotate into place -arrow-.
4. Insert washers and align.

1. Insert threaded pieces.
2. Drive small bevel gear shaft into final position and secure.

Scheme 1267

1. Insert large bevel gears with thinnest shims (0.5 mm).
2. Insert small bevel gears at a 180° offset with thrust washers.

Note. Do not now interchange bevel gears and thrust washers.

1. Drive in shaft for bevel gears.
2. Press small bevel gears outward.
3. Press large bevel gears in direction of -arrow- and check play.
4. Ascertain the thickest - just fitting - shim for large bevel gears on each side.

1. Select required shims from table. Part numbers

The following shims are available

Scheme 1268

The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the differential bevel gears -arrow-.

Scheme 1269

Special tools and workshop equipment required

1. VW 391 Puller
2. VW 401 Thrust plate
3. VW 402 Thrust plate
4. VW 407 Punch

1. VW 408 A Punch
2. VW 412 Thrust disc

Scheme 1270

Special tools and workshop equipment required

1. VW 457 Supporting channels
2. VW 460 Removal device
3. VW 470/1 Assembly ring
4. VW 519 Sleeve

1. VW 540 Holding fixture
2. 30-205 Thrust pad

Scheme 1271

Special tools and workshop equipment required

1. 2003/3 Inserter ring
2. 3005 Thrust pad
3. 3028 Retainer
4. 3062 Thrust pad

1. 3138 Drift
2. 3143 Seal driver-Frt wheel bearing

Scheme 1272

Special tools and workshop equipment required

1. VW 771 Slide hammer-complete set
2. 3026 Mandrel
3. 3253 Wheel bearing assembly set
4. V.A.G 1383 A Engine/transmission jack

Note. Replace both taper roller bearings together. Install new taper roller bearings in delivery condition and do not oil additionally. When replacing the parts marked with 1) adjustment work is required. Refer to Adjustment overview .

1 - Nut

1. Unscrewing. (Scheme 1275)
2. Screwing in. see scheme 108
3. Measuring friction torque. (Scheme 1284)
4. Securing. (Scheme 1285)

2 - Flange for drive shaft

1. Pulling off. (Scheme 1276)
2. Installing. (Scheme 1283)

3 - Sealing ring

1. Pulling out. (Scheme 1277)
2. Tapping in. see scheme 106

4 - O-ring

1. Replace
2. Insert with gear oil. (Scheme 1282)

5 - Inner race for small taper roller bearing 1)

1. Pressing out drive pinion. (Scheme 1278)
2. Pressing on. see scheme 104

6 - Outer race for small taper roller bearing 1)

1. Pulling out. (Scheme 1279)
2. Pressing in. see scheme 103

7 - Spacer sleeve 1)

1. Replace

8 - Final drive housing 1)

9 - Shim "S3"

1. Note thickness
2. Adjustment overview. Refer to «Adjustment overview»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__adjustment-overview) .

10 - Outer race for large taper roller bearing 1)

1. Tapping out. (Scheme 1280)
2. Inserting. see scheme 102

11 - Inner race for large taper roller bearing 1)

1. Pressing off. (Scheme 1281)
2. Pressing on. see scheme 101

12 - Drive pinion 1)

1. Is mated with ring gear, replace together as a set

Scheme 1273

1. Secure final drive on a repair stand. Refer to «Secure complete rear final drive on a repair stand with bracket VW 540»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .
2. Screw in two hexagon nuts M8 x 30 -A-.

B - Socket, long A/F 36

1. When nut is loosened the final drive must be supported (e.g. with universal transmission mounting 1359/2 in conjunction with engine/transmission jack V.A.G 1383 A).

Pulling flange for drive shaft off drive pinion

1. Screw two hex nuts M8 x 30 -A- into the flange.

Scheme 1274

Scheme 1275

B - Support, e.g. Kukko 22/2

B - Internal puller 46 to 2.28 in, e.g. Kukko 21/7

Scheme 1276

1. After removing check shims for damage.

Scheme 1277

A - Separating device 22 to 4.53 in, e.g. Kukko 17/2

Scheme 1278

1. Heat inner race to approx. 100°C, position and push to final position.

Scheme 1279

1. Lightly lubricate bearing seat in housing.
2. Insert predetermined shim "S3" for drive pinion. Refer to «Adjustment overview»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__adjustment-overview) .

The inscription "top" on pressure plate 3253/4 faces nut of insertion device

Scheme 1280

1. Lightly lubricate the bearing seat in the housing.
2. The outer race must be attached with needle bearing drift VW 295 and thrust pad 30-205.

Scheme 1281

1. Insert new drive pinion with a new spacer sleeve.

1. Heat inner race for small taper roller bearing to approx. 100°C and install onto drive pinion.
2. Press up drive pinion and insert bearing with sleeve 40-21 onto stop.

Inserting O-ring

1. Insert O-ring with gear oil.

Tapping in seal for flange for drive shaft

1. Lightly oil outer circumference of seal.
2. Drive in seal onto stop with Mandrel 3026.
3. Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.

Installing flange

1. Drive shaft flange onto drive pinion until securing nut can be mounted.

Tighten nut for drive pinion and adjusting friction torque

1. Screw in two hex nuts M8 x 30 -A-.

B - Socket, long A/F 36

1. When the nut is tightened the final drive must be supported (e.g. with universal transmission mounting 1359/2 in conjunction with engine/transmission jack V.A.G 1383 A).

Note. Only increase tightening torque slowly and read-off frictional torque frequently. If the specified frictional torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. It is not possible to re-use a spacer sleeve that has been excessively compressed.

Scheme 1282

Note. Do not lubricate new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.

With torque gauge, 0 to 600 Ncm, standard commercially available

B - Socket, A/F 36

Note. Use 3/4" to 1/2" reducer as necessary.

The following frictional torques should be set

1) With at least 50 km service

Removing nut for drive pinion

1. When the nut has been locked the radial run-out on the drive shaft flange should be measured. Refer to «Drive shaft flange, measuring and marking radial run-out»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-flange-measuring-and-marking) .

Drive pinion and ring gear, adjusting

Note. Careful adjustment of the drive pinion and ring gear is important for the service life and smooth running of the final drive. For this reason, the drive pinion and ring gear are matched together during manufacture, and checked to ensure a good mesh pattern and quiet running in both directions of rotation. The position of quietest running is found by moving the drive pinion in an axial direction and at the same time lifting the ring gear out of the zero-play mesh position by the amount necessary to maintain the backlash within the specified tolerance. The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test machine in production. The deviation "r", which is related to the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear. The final drive set (drive pinion and ring gear) must only be replaced together as a matched pair. Observe the general repair instructions for taper roller bearings and shims. Maximum care and cleanliness are essential for achieving good results when performing repairs and taking measurements.

Scheme 1283

1 - Marking "0937" indicates Oerlikon final drive set with transmission ratio 37 : 9.

Note. Klingelnberg final drives "K937" or Gleasen final drives "G937" can be installed.

2 - Gear set pairing number (312).

3 - Deviation (tolerance) "r" is based on the test machine master gauge used in production. The deviation "r" is always given in 1/100 mm. Example: "25" means r = 0.25 mm

Ro - Length of adjustment master "Ro" of tester used.

Ro - Ring gear = 57.50 mm

R - Actual dimension between ring gear and face of pinion shaft at point with quietest running for this gear set. R = Ro + r

Vo - Hypoid offset

Scheme 1284

Note. Adjustment overview when Replacing individual components of transmission. Refer to Adjustment overview .

S1 - Adjustment shim for ring gear in cover for final drive

S2 - Shim for ring gear in final drive housing

S3 - Shim for drive pinion in final drive housing

Adjustment overview

Note. If performing assembly work on the final drive it is only necessary to adjust the drive pinion or final drive set if components have been replaced which have a direct effect on the adjustments of the final drive. To eliminate unnecessary adjustments observe following table

1) Shims; installation position. Refer to Position of shims .

2) Drive pinion and ring gear; only replace together.

Final drive, readjustment sequence

The following procedure is recommended to save time when the drive pinion and ring gear have to be adjusted

Note. Overview of components and shims. Refer to Position of shims .

Drive pinion, adjusting

Special tools and workshop equipment required

Scheme 1285

1. VW 385 Universal measuring tool

1. VW 540 Engine and transmission support

Note. Before adjusting the drive pinion adjust the ring gear (ascertain total shim thickness "S" for shims "S1" + "S2"). Refer to Ring gear, adjusting . Re-adjustment of the drive pinion is only necessary if the final drive set, taper roller bearing for drive pinion or housing for final drive is replaced. Adjustments. Refer to Adjustment overview . Do not oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.

Determining shim "S3" thickness

(Setting preload of taper roller bearing for drive pinion)

1. Clamp final drive into assembly bracket. Refer to «Rear final drive, attaching to assembly bracket»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive).
2. Insert both outer races for the taper roller bearing without shims into the housing. see scheme 102and see scheme 103

1. Insert drive pinion without spacer sleeve.
2. Heat inner race for taper roller bearing to approx. 100°C and install onto drive pinion.

Note. Only install spacer sleeve for final frictional torque measurement (after determining shim "S3"). Install new taper roller bearings in delivery condition and do not oil.

1. Mount flanges for drive shaft and tighten hex nut for the flange. (Scheme 1283)

A - Torque gauge, commercially available, 0 to 600 Ncm

B - Socket, A/F 36

1. Tighten drive pinion nut until the following frictional torque is obtained.

1) With at least 50 km service

Scheme 1286

1. Set adjustment ring of universal mandrel VW 385/1.

1. Distance a = 60 mm

1. Set sliding adjustment ring.

1. Distance b = 55 mm

Scheme 1287

1. Assemble universal mandrel as illustrated.

1. Dial indicator extension VW 385/15 = 9 mm long

1. Set universal master gauge VW 385/30.

1. Ro = 57.50 mm

1. Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
2. Turn drive pinion 8 turns in both directions so that the taper roller bearings settle.

Scheme 1288

1. Place end measuring plate VW 385/33 onto drive pinion head.

Scheme 1289

1. Remove master gauge and insert measuring mandrel in the housing.

1. The centering disc for VW 385/3 faces toward cover for final drive

1. Install cover for final drive and tighten 4 bolts.
2. Using adjustable ring, move 2nd centering disc out as far as possible so that the mandrel can still just be turned by hand.

Determining measurement "e"

Scheme 1290

1. Turn mandrel until the dial indicator point touches the end measuring plate on pinion shaft head, then measure maximum deflection (return point). The measured value is dimension "e" (in red range).

1. Measurement in following example: "e" = 1.60 mm

Note. Dimension "e" is required to determine thickness of shim "S3".

1. Then, (after removing universal mandrel) check again that the dial indicator, with master gauge VW 385/30 installed, indicates "0" with 2 mm preload, otherwise repeat the measurement.

Determining shim thickness "S3"

1. Determine shim(s) as accurately as possible from table. Part numbers

The following shims are available for "S3"

1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if necessary.

1. Remove universal mandrel.
2. Remove drive pinion and outer race for large taper roller bearing and reinstall with calibrated shims "S3" and spacer sleeves. (Scheme 1275)
3. Insert inner race for small taper roller bearing and tighten drive pinion nut until specified frictional torque is achieved. see scheme 108

Note. Do not oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer. Only increase tightening torque slowly and read-off frictional torque frequently. If the specified frictional torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. It is not possible to re-use a spacer sleeve that has been excessively compressed.

1. Set to following frictional torques

1) With at least 50 km service

Performing check measurement

Checking dimension "r"

1. Turn drive pinion 8 turns in both directions so that the taper roller bearings settle.

1. Insert universal mandrel and check measurement.

1. If the shims have been correctly selected, the dial indicator, reading counter clockwise (in red range), will show deviation "r" within a tolerance of ± 0.05 mm

1. Peen drive pinion nut with a punch.
2. The radial run-out at flange for drive shaft must always be measured and marked. Refer to «Drive shaft flange, measuring and marking radial run-out»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__drive-shaft-flange-measuring-and-marking) .

Scheme 1291

(Adjusting differential)

Special tools and workshop equipment required

1. VW 385/17 Magnetic plate 50 mm dia.
2. VW 387 Dial gauge holder
3. VW 388 Measuring lever
4. VW 521 Adjustment tool for ring gear

1. V.A.G 1331 Torque wrench

It is necessary to readjust the ring gear when

Final drive housing, cover for final drive, taper roller bearing for differential, differential housing or drive pinion are replaced.

Adjustment overview. Refer to Adjustment overview

Note. Differential taper roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal". Do not oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.

Determining total shim thickness "Stotal" for shims "S1" + "S2"

(Setting preload of taper roller bearing for differential)

1. Drive pinion is removed!

Note. If only the taper roller bearings for the differential are being replaced, the ring gear can be removed from the differential housing. The pinion shaft does not need to be removed.

1. Pry out seals for flange shaft using a suitable lever.
2. Remove outer races of differential taper roller bearings and remove shims. Refer to «Differential, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive)
3. Drive outer race/taper roller bearing for left differential (housing side) with shim "S2*" of thickness 1.00 mm into housing. Refer to «Differential, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .

Note. For measurement purposes a shim "S2" with a thickness of 0.04 in is initially inserted. It is referred to as "S2*" in the following. After determining the backlash "S2*" will be replaced by the correct "S2".

1. Drive outer race/taper roller bearing for right differential (cover side) without shim in onto stop. Refer to «Differential, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive) .
2. Insert differential into housing. The ring gear is positioned on the right side (cover side).
3. Install cover and tighten bolts to 25 Nm.

Scheme 1292

1. Install special tools VW 521/4 and 521/8 onto housing side in differential housing.
2. Turn cover side of differential housing upward.
3. Turn differential 8 turns in both directions so that the taper roller bearings settle.
4. Place measuring plate VW 385/17 onto differential.

Scheme 1293

1. Install measuring tools.

A - Dial indicator extension approx. 30 mm long

B - Hex bolt M8 x 45

1. Position dial indicator extension in middle of measuring plate VW 385/17.
2. Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.

Scheme 1294

1. Lift differential without turning; read off play on dial indicator and write it down.

1. Measurement in following example: 0.50 mm

1. If you want to repeat the measurement differential 8 turns in both directions so that the taper roller bearings settle.

Determine "Stotal" (S1 + S2)

Determining thickness of shim "S1*"

Note. The preliminary adjustment shim "S1*" will be replaced with the final shim "S1" after determining the backlash. The total shim thickness "Stotal" remains the same.

1. Define shim(s) as precisely as possible based on the table. Refer to «The following shims are available for "S1"»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive__the-following-shims-are-available-for) .

Measuring frictional torque (check)

1. Pinion shaft removed
2. Differential installed with shims "S1*" and "S2*"

Scheme 1295

1. Install torque gauge 0 to 600 Ncm -A- onto differential.
2. Read off friction torque.

Frictional torque specified values

1) With at least 50 km service

Note. Differential taper roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal". Do not oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer. If the final drive set is being re-adjusted, the adjustment of the pinion shaft should be performed now, and the adjustment should be checked. Refer to Drive pinion, adjusting .

Adjusting backlash

1. Drive pinion with shim "S3" installed
2. Differential with shims "S1*" + "S2*" installed

1. Insert differential into final housing mount cover and tighten all bolts to 25 Nm.
2. Turn differential 5 turns in both directions so that the taper roller bearings settle.

Scheme 1296

1. Install measuring tools.
2. Use dial indicator extension VW 382/10 (6 mm flat).
3. Set measuring lever VW 388 to dimension "a" = 60 mm.
4. Measure play between teeth flanks (backlash) as follows

1. Turn ring gear until it makes contact with a tooth flank (end of backlash travel).
2. Preload dial indicator to 1 mm and set to zero.
3. Turn ring gear back until lying against an opposite tooth flank (backlash).
4. Read off backlash and note value.

1. Turn ring gear through 90° and repeat measurements a further 3 times.

Determining average backlash

1. Result: The average backlash is 1.16 divided by 4 = 0.29 mm

Note. If the individual measurements differ by more than 0.06 mm from each other, the installation of the ring gear or the final drive set itself is not correct. Check installation; replace final drive set, if necessary.

Determining thickness of shim "S2"

1. Determine shim(s) as accurately as possible from table. Part numbers

The following shims are available for "S2"

1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if necessary.

Determining thickness of shim "S1"

1. Determine shim(s) as accurately as possible from table. Part numbers

The following shims are available for "S1"

1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if necessary.

Check measurement

1. Drive pinion with shim "S3" installed
2. Differential with shims "S1" (cover side) + "S2" (housing side) installed

1. Turn differential 5 turns in both directions so that the taper roller bearings settle.
2. Measure backlash four times on circumference.

1. Specification: 0.12 to 0.22 mm

Note. If the backlash is beyond the tolerance, the adjustments must be repeated. Refer to Determining thickness of shim "S2" . The total shim thickness "Stotal" must not be changed. The individual measurements must not differ by more than 0.06 mm from each other.

See also:
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS
• 42 - REAR SUSPENSION
• Allocation of mechanical units: 5-speed Manual Transmission 01A AWD
• Gear oil level in rear final drive, checking
• Drive shaft flange, measuring and marking radial run-out
• Drive shaft, removing and installing
• Installing
• Adjustment overview
• Drive pinion, adjusting
• Adjusting backlash
• The following shims are available for "S1"
• Determining thickness of shim "S2"