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Final Drive, Differential (Continuously Variable Transmission Internal Components 0aw (sedan)) Audi A4 B8

Axle Shafts 50 illustrations ~3554 words

FRONT FINAL DRIVE SEALING RINGS OVERVIEW

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

Scheme 373

Scheme 373: FRONT FINAL DRIVE SEALING RINGS OVERVIEW
Scheme 373: FRONT FINAL DRIVE SEALING RINGS OVERVIEW
  1. Shaft Seal For the left flange shaft Removing and installing, refer to «LEFT FLANGE SHAFT SEAL»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft-seal)
  2. Differential
  3. Bolt Replace Tightening specification and sequence (Scheme 374)
  4. Shaft Seal For the right flange shaft Removing and installing, refer to «RIGHT FLANGE SHAFT SEAL»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__right-flange-shaft-seal)
  5. Right Flange Shaft Removing and installing with the transmission installed, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-0aw-sedan) Refer to «RIGHT FLANGE SHAFT, WITH TRANSMISSION REMOVED»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__right-flange-shaft-with-transmission-removed)
  6. Locking Ring Replace
  7. Fill and Inspection Plug 30 Nm Replace For the transmission fluid inside the front final drive
  8. Cover For the front final drive Pay attention to the alignment sleeves Removing and installing, refer to «LEFT FLANGE SHAFT SEAL»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft-seal) After removing the front final drive cover, perform a pre-filling, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-0aw-sedan)
  9. O-ring On the front final drive cover Replace
  10. Bolt 10 Nm
  11. Gearshift Lever
  12. Shaft Seal For the gearshift shaft Removing and installing, refer to «SELECTOR SHAFT SEAL»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__selector-shaft-seal)
  13. Transmission
  14. Left Flange Shaft Removing and installing, refer to «LEFT FLANGE SHAFT»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft)
  15. Bolt 10 Nm plus an additional 90° turn Replace
  16. Bracket For the left flange shaft Attached to the left flange shaft with the ball bearing -17- and the circlip -18- Check for traces of wear on the bearing bracket and check the pretension on the ball bearing for the left flange shaft, refer to «LEFT FLANGE SHAFT BALL BEARING PRETENSION, CHECKING»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft-ball-bearing-pretension) Removing and installing, refer to «LEFT FLANGE SHAFT BALL BEARING MOUNTING BRACKET»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft-ball-bearing-mounting).
  17. Ball Bearing For the left flange shaft Left flange shaft ball bearing pretension, checking, refer to «LEFT FLANGE SHAFT BALL BEARING PRETENSION, CHECKING»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft-ball-bearing-pretension) Removing and installing, refer to «LEFT FLANGE SHAFT BALL BEARING MOUNTING BRACKET»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft-ball-bearing-mounting)
  18. Circlip Replace
  19. Shaft Seal For the input shaft Refer to «INPUT SHAFT SEAL»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft-seal)
  20. Dual Mass Flywheel Refer to «DUAL MASS FLYWHEEL»(/audi/a4/b8-2007-2012/remont/automatic-trans/#controls-housing-continuously-variable-transmission-internal-components-0aw-sedan__dual-mass-flywheel)

Scheme 374

Scheme 374
Scheme 374

Note. Replace bolts that are tightened to the specification.

Tighten the bolts in three steps in the sequence shown

StageBoltsTightening Specification/Additional Turn
1.1 through 103 Nm
2.1 through 1020 Nm
3.1 through 10Tighten 90° further

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Bracket for the Left Flange Shaft10 + 90°
Fill and Inspection Plug 130
Gearshift Lever10
1 Replace

Front Final Drive Cover - Tightening Specifications and Sequence

Note. Replace bolts that are tightened to the specification.

Tighten the bolts in three steps in the sequence shown

StageBoltsTightening Specification/Additional Turn
1.1 through 103 Nm
2.1 through 1020 Nm
3.1 through 10Tighten 90° further

LEFT FLANGE SHAFT BALL BEARING PRETENSION, CHECKING

Check the ball bearing pretension using the wear pattern on the bearing bracket -arrow-.

Scheme 375

Scheme 375: LEFT FLANGE SHAFT BALL BEARING PRETENSION, CHECKING
Scheme 375: LEFT FLANGE SHAFT BALL BEARING PRETENSION, CHECKING

Note. The pretension on the left flange shaft ball bearing must be checked only on certain vehicles. Refer to the table for a list of the vehicles LEFT FLANGE SHAFT BALL BEARING PRETENSION, CHECKING This is not necessary on vehicles built later because they have been redesigned.

Scheme 376

Scheme 376: Wear Pattern "A"
Scheme 376: Wear Pattern "A"
  1. Small indentations near the hole on the bearing bracket -arrows-.
  2. No trace of wear or material erosion.

Optimize the pretension on the ball bearing for the left flange shaft. Refer to PRETENSION ON BALL BEARING, OPTIMIZING, LEFT FLANGE SHAFT .

Scheme 377

Scheme 377: Wear Pattern "B"
Scheme 377: Wear Pattern "B"
  1. Traces of wear, if necessary, with material erosion all around the hole on the bearing bracket -arrow-.

Adjust the pretension on the left flange shaft bearing. Refer to PRETENSION ON BALL BEARING, ADJUSTING, LEFT FLANGE SHAFT .

Replace the bearing bracket, the ball bearing and the circlip. Refer to LEFT FLANGE SHAFT BALL BEARING MOUNTING BRACKET .

PRETENSION ON BALL BEARING, OPTIMIZING, LEFT FLANGE SHAFT

Note. The pretension on the left flange shaft ball bearing must be optimized only on certain vehicles. Refer to the table for a list of the vehicles 1 This is not necessary on vehicles built later because they have been redesigned.

Procedure

  1. Left flange shaft removed, refer to «LEFT FLANGE SHAFT»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft) .

Conditions for optimizing

  1. The bearing bracket does not show any traces of wear or material erosion.
  2. Small indentations near the hole on the bearing bracket -arrows- are permissible.

Scheme 378

Scheme 378
Scheme 378
  1. Bearing bracket with wear pattern "A" (the bearing bracket does not shown any traces of wear or material erosion). Refer to «Wear Pattern "A"»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan) .
  2. A shim is inserted into the bearing seat on the transmission to optimize the pretension on the ball bearing.

Insert a shim 0B4 409 227 -1- into the bearing seat on the transmission before installing the flange shaft to improve the pretension.

Scheme 379

Scheme 379
Scheme 379

Install the left flange shaft LEFT FLANGE SHAFT => Installing .

PRETENSION ON BALL BEARING, ADJUSTING, LEFT FLANGE SHAFT

Special tools and workshop equipment required

  1. Straight Edge 500 mm VAS 6075

Note. The pretension on the left flange shaft ball bearing must be optimized only on certain vehicles. Refer to the table for a list of the vehicles LEFT FLANGE SHAFT . This is not necessary on vehicles built later because they have been redesigned.

  1. Left flange shaft removed, refer to «LEFT FLANGE SHAFT»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft) .
  2. Bearing bracket with wear pattern "B" «LEFT FLANGE SHAFT BALL BEARING PRETENSION, CHECKING»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft-ball-bearing-pretension) (traces of wear if necessary with material erosion all around the hole).
  3. The bearing bracket and ball bearing must be replaced. Refer to «LEFT FLANGE SHAFT BALL BEARING MOUNTING BRACKET»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__left-flange-shaft-ball-bearing-mounting) .

Procedure

Scheme 380

Scheme 380
Scheme 380

Clean off any dirt and corrosion from the contact surface -arrow- using 150 grain sand paper.

Note. It is not necessary to sand the contact surfaces all the way down to bare metal. It is enough to just remove any dirt and corrosion.

Clean the contact surface and bearing seat.

Install the new left flange shaft ball bearing -arrow- into the bearing seat.

Scheme 381

Scheme 381
Scheme 381

Next procedure

  1. By bearing oversize (the bearing sticks out slightly above the contact surface) «PRETENSION ON BALL BEARING, ADJUSTING, LEFT FLANGE SHAFT»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__pretension-on-ball-bearing-adjusting-left) .
  2. With bearing undersize (the bearing sits deeper than the contact surface) «PRETENSION ON BALL BEARING, ADJUSTING, LEFT FLANGE SHAFT»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__pretension-on-ball-bearing-adjusting-left) .

Scheme 382

Scheme 382: Procedure if there is Bearing Oversize
Scheme 382: Procedure if there is Bearing Oversize

Place VAS 6075 straight across the bearing and determine the distance to the contact surface on the transmission housing on both sides with the feeler gauge.

Write down the measured value.

Place the straight edge 90° offset across the bearing and determine the distance to the contact surface on the transmission housing on both sides with the feeler gauge.

Write down the measured value.

Selecting the Shim(s)

Note. Use the smallest value take from the four values to select the shim(s).

  1. Specified value, bearing oversize = 0.5 to 0.8 mm
Smallest bearing oversize (example = 0.1 mm)
+Shim(s) thickness, (thickness = 0.3 mm)
=Bearing pre-load, (specified value = 0.5 to 0.8 mm)

Example

1 shim

0.1 mm + 0.3 mm = 0.4 mm, "bearing pre-load is too small"

2 shims

0.1 mm + 0.3 mm + 0.3 mm = 0.7 mm, "bearing pre-load is in the specified range"

  1. Result: Insert two 0.3 mm shims to reach the bearing pre-load = 0.7 mm within the 0.5 to 0.8 mm specified value.

Scheme 383

Scheme 383: Procedure if there is Bearing Undersize
Scheme 383: Procedure if there is Bearing Undersize

Note. The bearing under size can only be determined in the described procedure.

Place VAS 6075 straight across the contact surface on the transmission housing and measure the distance to the bearing on both sides with a feeler gauge.

Write down the measured value.

Place straight edge 50 mm offset across the contact surface on the transmission housing and measure the distance to the bearing on both sides with a feeler gauge.

Write down the measured value.

Selecting the Shim(s)

Note. Use the largest value taken from the four values to select the shim(s). Enter the measured bearing under size as negative value ("-") into the calculation.

  1. Specified value, bearing oversize = 0.5 to 0.8 mm
Larger determined bearing undersize (example -0.15 mm)
+Shim(s) thickness, (thickness = 0.3 mm)
=Bearing preload (specified value = 0.5 to 0.8 mm)

Example

1 shim

0.15 mm + 0.3 mm = 0, 15 mm, "bearing preload is too small"

3 shims

0.15 mm + 0.3 mm + 0.3 mm + 0.3 mm = 0.75 mm, "bearing pre-load is in the specified range"

  1. Result: A 0.75 mm bearing preload within the specified value of 0.5 to 0.8 mm is reached by installing three 0.3 mm shims.

Continuation for All

Scheme 384

Scheme 384
Scheme 384

Replace the bearing bracket, the ball bearing and the circlip. Refer to LEFT FLANGE SHAFT BALL BEARING MOUNTING BRACKET .

Insert the determined number of shims 0B4 409 227 -1- into the bearing seat on the transmission before installing the flange shaft.

Install the left flange shaft LEFT FLANGE SHAFT => Installing .

Scheme 385

Scheme 385: INPUT SHAFT, CHECKING FOR WEAR
Scheme 385: INPUT SHAFT, CHECKING FOR WEAR
  1. 3 - Lining Discs
  2. 6 - Pressure Plate Checking for wear (Scheme 386)
  3. 7 - Pistons Checking for wear (Scheme 386)
  4. 8 - Cover For the input shaft Checking (Scheme 390)
  5. 10 - Ball Bearing For the input shaft Replace the ball bearing after removing the input shaft cover
  6. 11 - Input Shaft Check running and sealing surfaces for wear (Scheme 387) Checking for signs of wear on the lining discs (Scheme 388)
  7. 13 - Oil Pipe Checking for wear (Scheme 389)

Scheme 386

Scheme 386
Scheme 386

Remove pistons -1- from thrust plate -2-.

Check the Thrust Plate -2

Check thrust plate running and sealing surfaces -arrow A- for wear.

Check thrust plate running and sealing surfaces -arrow D- for wear.

  1. If running or sealing surfaces -arrow A- show grooves, scratches or scoring, thrust plate -2- must be replaced.
  2. If running or sealing surfaces -arrow D- show grooves, scratches or scoring, thrust plate -2- and pistons -1- must be replaced.

Checking the Pistons -1

Check seal -arrow B- on outer piston circumference -1- for damage.

Check running surface -arrow C- on interior piston circumference -1- on shaft.

  1. If seal -arrow B- is damaged or piston running surface -arrow C- shows grooves, scratches, scoring or uneven thickness from wear, piston -1- must be replaced.

Scheme 387

Scheme 387
Scheme 387

Check input shaft running and sealing surfaces -arrow A- for wear.

Note. Shaft seal in input shaft cover seals at this sealing surface -arrow A-. Light scoring from shaft seal is normal.

Check the contact surface -arrow B- on the input shaft ball bearing inside the input shaft cover for wear.

Check shaft seal -arrow C- on the input shaft for damage.

  1. If seal -arrow C- is damaged or shaft running surfaces -arrow B- or -arrow A- show deep scoring or grooves, entire input shaft must be replaced.

Scheme 388

Scheme 388
Scheme 388

Check inner circumference of input shaft cylinder for scoring from lining discs -arrows-.

  1. If there is scoring on interior circumference of input shaft cylinder from lining discs -arrows-, entire input shaft must be replaced.

Scheme 389

Scheme 389
Scheme 389

Check oil pipe seal -1- for damage.

  1. The seal must have a gap -arrow B-.
  2. If the gap -arrow B- is completely closed, oil pipe must be replaced.

Check oil pipe running surfaces -arrows- and rotor blades -arrow A- for wear and damage.

  1. If seal -1- or rotor blades -arrow A- are damaged or contact surfaces -arrow- show deep scoring or grooves, oil pipe must be replaced.
  2. The O-ring -2- must be replaced.

Check the contact surface on the oil pipe in the suction jet pump.

Scheme 390

Scheme 390
Scheme 390

Check the contact surface on the cover -arrow- and the cover for damage.

  1. The contact surface must not show any damage.
  2. Input shaft cover must not be broken or cracked.

If the contact surface or the cover are damaged, then replace the input shaft cover.

LEFT FLANGE SHAFT

Special tools and workshop equipment required

  1. Puller T10037
  2. Slide Hammer-Complete Set VW 771
  3. Sealing grease G 052 128 A1

Removing

  1. The transmission is removed and mounted horizontally to the engine/transmission holder. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#controls-housing-continuously-variable-transmission-internal-components-0aw-sedan__transmission-securing-in-enginetransmission-holder) .

Tilt the transmission on the engine/transmission hold toward the rear so that no transmission fluid can drip out.

Remove the bolts -arrows- from the flange shaft mounting bracket.

Scheme 391

Scheme 391
Scheme 391

Remove the left flange shaft -2- from the transmission -arrow A-.

Scheme 392

Scheme 392
Scheme 392

Note. Ignore -1- and -arrow 3 and arrow B-.

Note. If it is not possible to remove the left flange shaft by hand, use the VW 771 to remove it. Attach the plate from the T10037 to the flange shaft -arrows- and attach the spindle from the VW 771 (nuts -A-).

Remove the dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

Scheme 393

Scheme 393: Installing
Scheme 393: Installing

Install in reverse order of removal. Note the following

  1. Tightening specification, refer to «FRONT FINAL DRIVE SEALING RINGS OVERVIEW»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__front-final-drive-sealing-rings-overview) .

Always clean the left flange shaft, the transmission housing in the area where the differential is accessed -arrow A- and the shaft seal -arrow B-.

Note. Replace the left flange shaft seal (between the differential and transmission housing) -arrow B- if it is damaged. Refer to LEFT FLANGE SHAFT SEAL .

Fill the space between the sealing and dust lip half way with sealing grease G 052 128 A1.

Clean the left flange shaft thoroughly.

The following work must be performed on the listed vehicle types up to the specified VIN

Vehicle ModelVINFactory
Audi A4 MY 08Through WAUZZZ8K9BN034383Germany, Neckarsulm
Audi A4 MY 08Through WAUZZZ8KXBA082742Germany, Ingolstadt
Audi A5 Cabriolet MY 2008Through WAUVGAFH3BN009542Germany, Neckarsulm
Audi A5 Coupe MY 08Through WAUZZZ8T9BA902081Germany, Ingolstadt

Check the pretension on the ball bearing for the left flange shaft based on the wear pattern on the bearing bracket -arrow-, refer to LEFT FLANGE SHAFT BALL BEARING PRETENSION, CHECKING .

  1. Optimize the pretension on the ball bearing for the left flange shaft if necessary, refer to «PRETENSION ON BALL BEARING, OPTIMIZING, LEFT FLANGE SHAFT»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__pretension-on-ball-bearing-optimizing-left) .
  2. Adjust the pretension on the ball bearing for the left flange shaft if necessary. Refer to «PRETENSION ON BALL BEARING, ADJUSTING, LEFT FLANGE SHAFT»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan__pretension-on-ball-bearing-adjusting-left) .

For All Vehicle Models

Install the dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

Rotate the dual mass flywheel -1- until the opening to the differential -arrow 3- is seen.

Install the left flange shaft -2- into the transmission -arrow B-. When doing this, insert the flange shaft centrally into the shaft seal on the front differential -arrow 3-.

Note. If the flange shaft is not centered, the flange shaft splines -2- will damage the left flange shaft seal between the final drive and the transmission housing. The shaft seal must be replaced if it is damaged. Ignore -arrow A-.

Tighten the bolts -arrows-.

Fill the gear oil in the front final drive after installing the transmission and check the level. Refer to General Information .

LEFT FLANGE SHAFT BALL BEARING MOUNTING BRACKET

Special tools and workshop equipment required

  1. Thrust Plate VW 401
  2. Thrust Plate VW 402
  3. Thrust Disc VW 412
  4. Tube 42 mm Dia. VW 516

Remove the left flange shaft. Refer to LEFT FLANGE SHAFT BALL BEARING MOUNTING BRACKET LEFT FLANGE SHAFT .

Scheme 394

Scheme 394
Scheme 394

Remove the locking ring -1- from the flange shaft.

Remove the ball bearing -A- from the flange shaft

Scheme 395

Scheme 395
Scheme 395

Install the new bearing bracket -1-.

Scheme 396

Scheme 396
Scheme 396
  1. Installed position: the printed side faces the drive axle flange

Install the new ball bearing -2-.

Install the ball bearing -A- all the way on with the bearing bracket -B- installed.

Scheme 397

Scheme 397
Scheme 397

Install the circlip -1- in the flange shaft groove.

RIGHT FLANGE SHAFT, WITH TRANSMISSION REMOVED

Note. The right flange shaft can be removed and installed with the transmission still installed. Refer to Removal and Installation .

Special tools and workshop equipment required

  1. Needle Bearing Drift VW 295
  2. Puller T10037
  3. Sealing grease G 052 128 A1

Removing

  1. The transmission is removed and mounted horizontally to the engine/transmission holder. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#controls-housing-continuously-variable-transmission-internal-components-0aw-sedan__transmission-securing-in-enginetransmission-holder) .

Remove right flange shaft by fastening T10037 to transmission housing -arrow-.

Scheme 398

Scheme 398
Scheme 398

Installing

Installation is performed in the reverse order of removal while observing the following

Always replace the flange shaft locking ring -A-.

Scheme 399

Scheme 399
Scheme 399

Clamp the flange shaft in a vise with jaw protectors. Use the new circlip -A- to press the previous circlip out of the flange shaft groove.

Check the right flange shaft seal -arrow- for damage and replace it if necessary. Refer to RIGHT FLANGE SHAFT SEAL .

Scheme 400

Scheme 400
Scheme 400

Fill the space between the sealing and dust lip half way with sealing grease G 052 128 A1.

Drive the flange shaft in using a VW 295.

Fill gear oil in the front final drive and check the level. Refer to General Information .

LEFT FLANGE SHAFT SEAL

Special tools and workshop equipment required

  1. Oil Collecting and Extracting Device V.A.G 1782
  2. Thrust Piece for Final Drive at Transmission T40164
  3. Sealing grease G 052 128 A1

Procedure

  1. The transmission is removed and mounted horizontally to the engine/transmission holder. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#controls-housing-continuously-variable-transmission-internal-components-0aw-sedan__transmission-securing-in-enginetransmission-holder) .

Place the V.A.G 1782 under the transmission.

Remove the right flange shaft. Refer to RIGHT FLANGE SHAFT, WITH TRANSMISSION REMOVED .

Remove the bolts -arrows- diagonally.

Scheme 401

Scheme 401
Scheme 401

Carefully remove the front final drive cover; when doing this, the transmission fluid will drain out.

CAUTIONDanger of causing damage to the differential. Slowly remove the differential from the transmission housing. Otherwise differential can fall out of transmission. A differential that has fallen out can no longer be installed. If differential falls out, the transmission must be replaced. Make sure the differential bearing race/tapered roller bearing and adjustment shims do not fall out of the transmission housing and final drive. Bearing races/tapered roller bearing and adjustments that have fallen out cannot be allocated with shop equipment.

Carefully remove the differential -arrow- and lay it on a soft support.

Scheme 402

Scheme 402
Scheme 402

Remove the left flange shaft. Refer to LEFT FLANGE SHAFT .

CAUTIONDanger of damaging the seating surface in the transmission housing. Position the screwdriver.

Pry out the seal from the back -arrow-.

Scheme 403

Scheme 403
Scheme 403

Lightly coat the new seal on the outside with oil and install it using the T40164.

Scheme 404

Scheme 404
Scheme 404
  1. The open side of the seal faces the T40164.

Install the shaft seal for the left flange shaft using the T40164 all the way; when doing this, do not bend it.

Fill the space between the sealing and dust lip half way with sealing grease G 052 128 A1.

Install the differential.

Replace the O-ring -A- on the front final drive cover and coat it with gear oil.

Scheme 405

Scheme 405
Scheme 405

Install the front final drive cover with a new O-ring and tighten the bolts to the tightening specification. (Scheme 374)

Install the left flange shaft. Refer to LEFT FLANGE SHAFT .

Install the right flange shaft. Refer to RIGHT FLANGE SHAFT, WITH TRANSMISSION REMOVED .

The front final drive must be pre-filled with gear oil before installing the transmission. Refer to General Information .

CAUTIONThere is a risk of damaging the transmission. There are different gear oils for the "0AW transmission". Only gear oil available as a replacement part meant for the transmission code may be used. Do not mix the axles oil, not even in small quantities. This will cause the sealing rings to leak. Note the allocation of the axle oils according to the transmission code letters. Only axle oil for "0AW transmission" which can be obtained as a replacement part must be used in front final drive. Replace the filler plug after checking the level. Always pay attention to the allocation according to the transmission code. Compare the old and new filler plug to prevent leakage on the transmission. Do not mix other gear oils, even in small quantities. Leaks in the transmission will result.

Fill the gear oil in the front final drive after installing the transmission and check the level. Refer to General Information .

RIGHT FLANGE SHAFT SEAL

Special tools and workshop equipment required

  1. Thrust Piece T40163
  2. Pry lever

Procedure

Remove the right flange shaft. Refer to RIGHT FLANGE SHAFT, WITH TRANSMISSION REMOVED .

Pry out the flange shaft sealing ring -arrow-.

Lightly coat the outer circumference of the new shaft seal with oil.

Install the shaft seal for the right flange shaft all the way in using the T40163. Be careful not to bend it while installing.

Scheme 406

Scheme 406
Scheme 406

Fill the space between the sealing and dust lip half way with sealing grease G 052 128 A1.

Install the right flange shaft. Refer to RIGHT FLANGE SHAFT, WITH TRANSMISSION REMOVED .

SELECTOR SHAFT SEAL

Special tools and workshop equipment required

  1. Tube 31.5 mm Dia. VW 418 A
  2. Puller T40188

Procedure

  1. The transmission is removed and mounted horizontally to the engine/transmission holder. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#controls-housing-continuously-variable-transmission-internal-components-0aw-sedan__transmission-securing-in-enginetransmission-holder) .

Mark the installation position of the selector shaft lever -A- on the selector shaft with a water-proof marker.

Scheme 407

Scheme 407
Scheme 407

Note. This prevents an incorrect installation.

Remove the bolt -B- and the gearshift lever -A- upward.

CAUTIONDanger of damaging the selector shaft, illustrated here from behind with the hydraulic control unit removed. The selector shaft must not be pushed into or pulled out of the transmission. The shifting cam -1- on the selector shaft will break off if the selector shaft is forced up or down. The transmission must be replaced if the shifting cam is damaged.

Scheme 408

Scheme 408
Scheme 408

Mount the nut T40188/1 on the puller T40188/2.

Scheme 409

Scheme 409
Scheme 409

Mount the T40188/2 over the selector shaft.

Push the T40188/2 at the same time into the sealing ring -A- -arrow 1- and install it -arrow 2-.

Note. In order to be able to exert stronger force in direction -arrow 1-, the T40188/1 was mounted on the T40188/2. The T40188/2 cuts into the sealing ring -A-. The transmission sealing surface and selector shaft must not be damaged.

  1. The T40188/2 must fit securely in the sealing ring; insert the T40188/2 and turn it again if necessary.

Mount the T40188 and align it with the side threaded feet.

Scheme 410

Scheme 410
Scheme 410
  1. The T40188 must aligned so that the T40188/1 can be flat.
  2. It is necessary to maintain the 8 mm distance -X- between the lower edge of the traverse and the T40188/2. Place a washer as a spacer between the transmission and the threaded feet.

Note. The space is necessary so that the sealing ring can be pulled up over the traverse. The T40188/2 will get damaged if it contact the traverse before the sealing ring is completely removed.

Install the T40188/1 and remove the selector shaft sealing ring -A-.

Clean the opening and remove any metal particles with a vacuum.

Coat the outer diameter and the sealing lip of the new sealing ring with ATF.

Scheme 411

Scheme 411
Scheme 411

Slide on new shaft seal over selector shaft and press in.

Drive in the shaft seal until it stops using VW 418 A.

Connect lever for transmission shift lever -A- according to the marking to the selector shaft and tighten bolt -B-.

Bolt tightening specification, refer to FRONT FINAL DRIVE SEALING RINGS OVERVIEW .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 412

Scheme 412: SPECIAL TOOLS
Scheme 412: SPECIAL TOOLS

Scheme 413

Scheme 413
Scheme 413

Scheme 414

Scheme 414
Scheme 414

Scheme 415

Scheme 415
Scheme 415

Scheme 416

Scheme 416
Scheme 416

Scheme 417

Scheme 417
Scheme 417

Scheme 418

Scheme 418
Scheme 418

Scheme 419

Scheme 419
Scheme 419

Scheme 420

Scheme 420
Scheme 420

Scheme 421

Scheme 421
Scheme 421

Scheme 422

Scheme 422
Scheme 422
  1. Thrust Plate VW 401
  2. Thrust Plate VW 402
  3. Thrust Disc VW 412
  4. Tube 42 mm Dia. VW 516
  5. Needle Bearing Drift VW 295
  6. Puller T10037
  7. Oil Collecting and Extracting Device V.A.G 1782
  8. Thrust Piece T40163
  9. Thrust Piece for Final Drive at Transmission T40164
  10. Tube 31.5 mm Dia. VW 418 A
  11. Puller T40188
  12. Not illustrated
  13. Puller T10037
  14. Straight Edge 500 mm VAS 6075
  15. Slide Hammer-Complete Set VW 771

Edition 1 30 2011

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