Final Drive, Differential (Automatic Transmission 0b6 (coupe)) Audi A5 I

GEAR OIL LEVEL IN FRONT FINAL DRIVE, CHECKING AND FILLING

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782
2. Protective eyewear

Procedure

1. Gear oil temperature at approximately 20 °C (68 °F) (room temperature).
2. Move the vehicle onto a 4-column shop hoist or over a work pit so it is completely level.
3. Tightening specification, refer to «FRONT FINAL DRIVE OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__front-final-drive-overview) .

Note. General repair instructions, refer to REPAIR INFORMATION . Automatic transmission clean working conditions, refer to CLEAN WORKING CONDITIONS . Always maintain the specified transmission fluid level; the transmission is very sensitive to overfilling. Follow all applicable disposal regulations.

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

Remove the plug -arrow-.

Scheme 1

1. Specified value: The oil level is correct when the front final drive is filled to the lower edge of the filler opening.

Allow the excess gear oil to drain if necessary.

Add gear oil if necessary until it runs out of the gear oil filler hole.

1. For the correct transmission fluid .

Note. Replace the drain plug and gasket.

Tighten the new sealing plug.

GEAR OIL IN FRONT FINAL DRIVE, FILLING AFTER REPAIR

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782
2. Protective eyewear

Filling

1. The front final drive cover was removed and all of the gear oil has drained through it.
2. Move the vehicle onto a 4-column shop hoist or over a work pit so it is completely level.
3. Gear oil temperature at approximately 20 °C (68 °F) (room temperature).
4. Tightening specification, refer to «FRONT FINAL DRIVE OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__front-final-drive-overview) .

Note. General repair instructions, refer to REPAIR INFORMATION . Automatic transmission clean working conditions, refer to CLEAN WORKING CONDITIONS .

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

Remove the plug -arrow-.

Fill the front final drive with gear oil slowly over a period of at least 5 minutes until oil drips from the bottom of the inspection opening.

1. For the correct transmission fluid .

Note. A filling time of at least 5 minutes is required so that the internal oil level between the differential and oil fill space can equalize. Replace the drain plug and gasket.

Tighten the new sealing plug.

Note. It is not necessary to check the oil level again at this stage.

GEAR OIL LEVEL IN TRANSFER CASE, CHECKING AND FILLING

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782
2. Protective eyewear

Procedure

1. Gear oil temperature at approximately 20 °C (68 °F) (room temperature).
2. Move the vehicle onto a 4-column shop hoist or over a work pit so it is completely level.
3. The transmission must be still for at least 15 minutes to make sure the oil settles internally.
4. Tightening specification, refer to «CENTER DIFFERENTIAL HOUSING OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__center-differential-housing-overview) .

Note. General repair instructions, refer to REPAIR INFORMATION . Automatic transmission clean working conditions, refer to CLEAN WORKING CONDITIONS .

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

Remove the locking bolt -arrow- on the side of the center differential housing.

Scheme 2

1. Specified value: The level is correct when the transmission fluid comes up to the bottom edge of oil filler hole.

Allow the excess gear oil to drain if necessary.

Add gear oil if necessary until it runs out of the gear oil filler hole.

1. For the correct transmission fluid .

Repeat the process in steps every 15 seconds with 50 ml of gear oil until the transfer case stops accepting gear oil.

Note. The inside of the transfer case is divided into several oil chambers. The waiting period is necessary to ensure they are all filled evenly. Replace the drain plug and gasket.

Tighten the new sealing plug.

TRANSFER CASE GEAR OIL, FILLING AFTER REPAIR

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782
2. Protective eyewear

Work sequence

1. The gear oil in the transfer case was drained.
2. The center differential housing was removed and all of the gear oil drained.
3. Move the vehicle onto a 4-column shop hoist or over a work pit so it is completely level.
4. The transmission must be still for at least 15 minutes to make sure the oil settles internally.
5. Gear oil temperature at approximately 20 °C (68 °F) (room temperature).
6. Tightening specification, refer to «CENTER DIFFERENTIAL HOUSING OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__center-differential-housing-overview) .

Note. General repair instructions, refer to REPAIR INFORMATION . Automatic transmission clean working conditions, refer to CLEAN WORKING CONDITIONS .

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

Remove the locking bolt -arrow- on the side of the center differential housing.

Note. Do not start the engine or tow the vehicle if there is no gear oil in the transmission.

1. For the correct transmission fluid .

Fill the transfer case with gear oil slowly and evenly over a period of least 5 minutes until gear oil flows out at the lower edge of the filling opening.

Note. A filling time of at least 5 minutes is required so that the internal oil level between the center differential and oil fill space can equalize.

Repeat the filling process in steps every 15 seconds with 50 ml of gear oil until the transfer case stops accepting gear oil.

Note. The inside of the transfer case is divided into several oil chambers. The waiting period is necessary to ensure they are all filled evenly. Replace the drain plug and gasket.

1. Specified value: The level is correct when the transmission fluid comes up to the bottom edge of oil filler hole.

Tighten the new sealing plug.

Tightening specification, refer to CENTER DIFFERENTIAL HOUSING OVERVIEW .

Note. It is not necessary to check the oil level again at this stage.

FRONT FINAL DRIVE OVERVIEW

Note. Automatic transmission clean working conditions, refer to CLEAN WORKING CONDITIONS . General repair instructions, refer to REPAIR INFORMATION .

Scheme 3

1. Left Flange Shaft Seal Between the final drive and the transmission housing Refer to «LEFT FLANGE SHAFT SEAL»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__left-flange-shaft-seal)
2. Adjusting Shim Behind the taper roller bearing outer race
3. Taper Roller Bearing Outer Race
4. Bolt Quantity: 11 Tightening specification and sequence, refer to «FRONT FINAL DRIVE COVER - TIGHTENING SPECIFICATIONS AND SEQUENCE»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__front-final-drive-cover-tightening)
5. Right Flange Shaft Seal Refer to «RIGHT FLANGE SHAFT SEAL»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__right-flange-shaft-seal)
6. Right Flange Shaft Refer to «RIGHT FLANGE SHAFT»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__right-flange-shaft)
7. Locking Ring Removing and installing
8. Drain Plug Replace 35 Nm For oil filler hole
9. Front Final Drive Cover Pay attention to the alignment sleeves
10. Adjusting Shim Behind the taper roller bearing outer race
11. Taper Roller Bearing Outer Race
12. O-ring On the front final drive cover Refer to «FRONT FINAL DRIVE COVER O-RING»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__front-final-drive-cover-o-ring)
13. Differential
14. Transmission
15. Spring Pin
16. Selector Shaft Lever
17. Selector Shaft Seal Refer to «SELECTOR SHAFT SEAL»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__selector-shaft-seal)
18. Left Flange Shaft Refer to «LEFT FLANGE SHAFT»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__left-flange-shaft)
19. Bolt 10 Nm plus an additional 45° turn
20. Gear Carrier Use the circlip to attach together with the mount -21- -22- to the left flange shaft. Is identified together as the left flange shaft mounting bracket.
21. Bearings For the left flange shaft
22. Circlip For the left flange shaft mount
23. Torque Converter Shaft Seal Refer to «TORQUE CONVERTER SHAFT SEAL»(/audi/a5/i-2007-2011/remont/automatic-trans/#torque-converter-automatic-transmission-0b6-awd-coupe__torque-converter-shaft-seal)
24. Torque Converter Refer to «TORQUE CONVERTER»(/audi/a5/i-2007-2011/remont/automatic-trans/#torque-converter-automatic-transmission-0b6-awd-coupe)

Scheme 4

Pre-tighten the bolts -1 and 2- to 3 Nm.

Tighten the bolts to 23 Nm in the following sequence: -1 through 11-.

CENTER DIFFERENTIAL HOUSING OVERVIEW

Scheme 5

1. O-ring Replace Coat with transmission fluid
2. Center Differential
3. Ball Bearing For the center differential Refer to «CENTER DIFFERENTIAL BALL BEARING»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__center-differential-ball-bearing)
4. Locking Ring For the flange shaft ball bearing
5. Locking Ring For the flange shaft
6. Ball Bearing For the rear flange shaft «REAR FLANGE SHAFT BALL BEARING»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__rear-flange-shaft-ball-bearing)
7. Drain Plug Replace 35 Nm For the oil filler hole in the center differential housing
8. Center Differential Housing Refer to «CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__center-differential-housing-transmission-installed)
9. Seal for the Rear Flange Shaft Refer to «REAR FLANGE SHAFT SEAL»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__rear-flange-shaft-seal)
10. Rear Flange Shaft Removing and installing, refer to «REAR FLANGE SHAFT SEAL»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__rear-flange-shaft-seal) When replacing the rear flange shaft, also replace the seal
11. Bolt Tightening specification and sequence, refer to «CENTER DIFFERENTIAL HOUSING - TIGHTENING SPECIFICATION AND SEQUENCE»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__center-differential-housing-tightening-specification) Removing and installing

CENTER DIFFERENTIAL HOUSING - TIGHTENING SPECIFICATION AND SEQUENCE

Tighten the center differential housing bolts in three steps as follows

Pre-tighten the bolts -1- and -2- to 3 Nm.

Scheme 6

Tighten the bolts to 8 Nm in the following sequence: -1 to 6-.

Tighten the bolt in the following sequence: -1 through 6- plus 90° additional turn.

FASTENER TIGHTENING SPECIFICATIONS

FRONT FINAL DRIVE COVER - TIGHTENING SPECIFICATIONS AND SEQUENCE

Pre-tighten the bolts -1- and -2- to 3 Nm.

Tighten the bolts to 23 Nm in the following sequence: -1 through 11-.

Tighten the center differential housing bolts in three steps as follows

1. Pre-tighten the bolts -1- and -2- to 3 Nm.

2. Tighten the bolts to 8 Nm in the following sequence: -1 to 6-.

3. Tighten the bolt in the following sequence: -1 through 6- plus 90° additional turn.

LEFT FLANGE SHAFT

Special tools and workshop equipment required

1. Engine and Transmission Holder VAS 6095

REMOVING

1. Secure the transmission to the VAS 6095. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-automatic-transmission-0b6-awd-coupe__transmission-securing-in-enginetransmission-holder) .

Tilt the transmission back on the engine/transmission holder so the transmission fluid does not drain out.

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

Scheme 7

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

Scheme 8

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

Remove the torque converter. Refer to TORQUE CONVERTER .

INSTALLING

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «FRONT FINAL DRIVE OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#final-drive-differential-automatic-transmission-0b6-coupe__front-final-drive-overview) .

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

Scheme 9

Note. Replace the shaft seal between the differential and transmission housing -arrow B- if it is damaged. Refer to FRONT FINAL DRIVE OVERVIEW .

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

Install the torque converter. Refer to TORQUE CONVERTER .

Rotate the torque converter -1- until the opening to the differential -arrow 3- is visible.

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 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 left flange shaft mounting bracket -arrows-.

Refer to GEAR OIL LEVEL IN FRONT FINAL DRIVE, CHECKING AND FILLING after installing the transmission.

RIGHT FLANGE SHAFT

Special tools and workshop equipment required

1. Needle Bearing Drift VW 295
2. Slide Hammer-Complete Set VW 771
3. Retainer 3419
4. Oil Collecting and Extracting Device V.A.G 1782
5. M10 nut, quantity: 2

Remove the right front wheel.

Remove the right drive axle cover -1- inside the wheel housing.

Scheme 10

Remove the bolts -arrows- and remove the heat shield from the right drive axle.

Scheme 11

Remove the right drive axle from the transmission flange shaft and move it back.

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

Install the threaded eye from the 3419 into the threaded hole in the right flange shaft with 2 M10 nuts -1-.

Scheme 12

Position the VW 771 with the pulling hook VW 771/13 on the threaded eye and remove the flange shaft.

Install in reverse order, paying attention to the following

Note. Replace the circlip on the right flange shaft.

Clamp the flange shaft in a vise with jaw protectors. Remove the old circlip from the groove in the flange shaft using the new circlip -A-.

Scheme 13

Drive the right flange shaft in using the VW 295.

Install right drive axle. Refer to Removal and Installation .

Install the drive axle heat shield, refer to Driveshaft Heat Shield - Tightening Specification .

Gear oil level in front final drive, checking and topping off. Refer to GEAR OIL LEVEL IN FRONT FINAL DRIVE, CHECKING AND FILLING .

LEFT FLANGE SHAFT SEAL

Note. A defective shaft seal will allow gear oil to enter the torque converter bell housing.

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782
2. Extractor Lever VW 681
3. Thrust Piece T10139

Procedure

1. Transmission removed and mounted to the engine/transmission holder. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a5/i-2007-2011/remont/transmission-control-systems/#controls-housing-automatic-transmission-0b6-awd-coupe__transmission-securing-in-enginetransmission-holder) .

Note. Automatic transmission clean working conditions, refer to CLEAN WORKING CONDITIONS . General repair instructions, refer to REPAIR INFORMATION .

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

Remove the right flange shaft. Refer to RIGHT FLANGE SHAFT .

Remove the front final drive cover in a sequence opposite the tightening sequence that is illustrated.

Remove the front final drive cover together with the tapered roller bearing outer race and the adjustment shim.

Note. The shim must be the correct size and must not be replaced by a shim with a different thickness.

Remove the differential.

Remove the outer race for the differential tapered roller bearing -1- and the shim -2- located behind it from the transmission housing by hand.

Scheme 14

Note. The shim must be the correct size and must not be replaced by a shim with a different thickness.

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

Scheme 15

Remove shaft seal.

Note. Extractor lever must be positioned behind both sealing lips of the shaft seal. Do not position at outer circumference of shaft seal, otherwise the contact surface in transmission housing will be damaged. Guide the release lever carefully while prying out.

Examine shaft seal seat in transmission housing for damage; if necessary rework.

Coat outer circumference and sealing lip of shaft seal with axle oil.

Note. Push shaft seal onto pressure piece so that the projecting sealing lip of seal faces the tool.

Drive on in new shaft seal as far as stop.

Scheme 16

Insert the shim -2- and the outer race for the differential tapered roller bearing -1- into the transmission housing by hand as far as the stop.

Replace the O-ring -arrow-.

Scheme 17

Insert the differential into the transmission housing.

If the tapered roller bearing outer race and the shim have fallen out of the front final drive cover

Lubricate the shim and tapered roller bearing outer race with gear oil and insert them into the front final drive cover as far as the stop.

Tighten the front final drive cover bolts, refer to FRONT FINAL DRIVE COVER - TIGHTENING SPECIFICATIONS AND SEQUENCE .

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

Install the right flange shaft. Refer to RIGHT FLANGE SHAFT .

Axle oil, adding to transmission after repair. Refer to GEAR OIL IN FRONT FINAL DRIVE, FILLING AFTER REPAIR .

RIGHT FLANGE SHAFT SEAL

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782
2. Extractor Lever VW 681
3. Thrust Piece T40189

Procedure

Note. Automatic transmission clean working conditions, refer to CLEAN WORKING CONDITIONS . General repair instructions, refer to REPAIR INFORMATION .

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

Remove the right flange shaft. Refer to RIGHT FLANGE SHAFT .

Remove the right flange shaft seal.

Scheme 18

Coat the outer circumference of the new shaft seal with axle oil.

1. Installed position: The open side of the shaft seal faces the transmission.

Drive on in new shaft seal as far as stop. When doing this, do not bend the shaft seal or install it on an angle.

Scheme 19

Install the right flange shaft. Refer to RIGHT FLANGE SHAFT .

Axle oil, adding to transmission after repair. Refer to GEAR OIL IN FRONT FINAL DRIVE, FILLING AFTER REPAIR .

SELECTOR SHAFT SEAL

Special tools and workshop equipment required

1. Pry Lever - Rmv Outside Mirror 80 - 200
2. Thrust Piece T10135

Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the 80 - 200.

Scheme 20

Note. Do not bend or kink the selector lever cable.

Remove the spring pin -1- on the selector shaft lever -2- -arrow- until it is possible to remove the lever from the shaft.

Scheme 21

Pierce shaft seal with a small screwdriver and pull out.

Scheme 22

Install in reverse order, paying attention to the following

Apply ATF to the circumference and the space between the sealing lips of the new shaft seal.

1. Installed position: Open side of shaft seal faces transmission.

Slide the shaft seal onto the selector shaft.

Press the new shaft seal on as far as the stop using the T10135 and assembly lever -A-. Make sure the shaft seal does not tilt when doing this.

Scheme 23

Install the spring pin on the selector shaft lever while it is still removed.

Slide the lever onto the selector shaft and install the spring pin.

Check the ATF level. Refer to ATF, CHECKING LEVEL AND CORRECTING .

FRONT FINAL DRIVE COVER O-RING

Note. Automatic transmission clean working conditions, refer to CLEAN WORKING CONDITIONS . General repair instructions, refer to REPAIR INFORMATION .

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782

Procedure

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

Remove the right flange shaft. Refer to RIGHT FLANGE SHAFT .

Remove the front final drive cover bolts in the sequence opposite the tightening sequence illustrated and remove the cover together with the tapered roller bearing outer race and shim.

Note. The shim must be the correct size and must not be replaced by a shim with a different thickness.

Replace the O-ring -arrow-.

Insert the differential into the transmission housing.

If the tapered roller bearing outer race and the shim have fallen out of the front final drive cover

Lubricate the shim and tapered roller bearing outer race with gear oil and insert them into the front final drive cover as far as the stop.

Tighten the front final drive cover bolts, refer to FRONT FINAL DRIVE COVER - TIGHTENING SPECIFICATIONS AND SEQUENCE .

Install the right flange shaft. Refer to RIGHT FLANGE SHAFT .

Axle oil, adding to transmission after repair. Refer to GEAR OIL IN FRONT FINAL DRIVE, FILLING AFTER REPAIR .

CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED

Special tools and workshop equipment required

1. Engine-/Gearbox Jack V.A.G 1383 A
2. Transmission Support T10337
3. Counterhold Tool T10172
4. Adapter T10172/5
5. Oil Collecting and Extracting Device V.A.G 1782
6. Torque Wrench V.A.G 1331
7. Protective eyewear

1. Transmission installed.

Note. General repair instructions, refer to REPAIR INFORMATION . Clean working conditions for the automatic transmission, refer to CLEAN WORKING CONDITIONS .

Loosen the quick-release fasteners -2 through 4- and remove the noise insulation. Refer to Removal and Installation .

Scheme 24

Note. Ignore -arrow-.

Vehicles with one front exhaust pipe: Disconnect exhaust system at double clamp -arrow-.

Scheme 25

Vehicles with 2 front exhaust pipes: Disconnect the exhaust system at the clamping sleeves -1 and 2-.

Scheme 26

Remove the bolts -arrows- and remove the driveshaft heat shield.

Scheme 27

Remove the bolt connecting the driveshaft to the transmission. To do this, use the T10172 and T10172/5.

Scheme 28

Press the driveshaft together with rear final drive; the universal joint is able to slide axially.

Tie the driveshaft to the side.

Support the transmission to the tunnel crossmember using the V.A.G 1383 A and T10337.

Remove the bolts from the tunnel crossmember -arrows-.

Scheme 29

Note. Shown without the V.A.G 1383 A.

Lower the transmission to dimension -a- using the V.A.G 1383 A.

Scheme 30

1. Dimension -a- = maximum 100 mm.

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

Note. The housing does not have an oil drain plug. The axle oil can only be drained by removing the housing.

Place a cloth on the tunnel crossmember so the oil does not leak onto it.

Loosen and remove the center differential housing bolts in the sequence -6 to 1- and drain the gear oil.

Secure the center differential -1- so it does not fall out or remove it toward the rear from the input shaft.

Scheme 31

Note. There are different versions of the center differential -1-.

Install in reverse order, paying attention to the following

Note. Replace the center differential housing O-ring.

If the center differential -1- was removed

Position the center differential on the input shaft splines. Rotate the center differential slightly when doing this.

Make sure the center differential can be turned by hand.

Place the housing with the input shaft installed on the center differential. Rotate the housing slightly if necessary.

Tighten the center differential housing bolts, refer to CENTER DIFFERENTIAL HOUSING - TIGHTENING SPECIFICATION AND SEQUENCE .

Clean and install the tunnel crossmember. Refer to TUNNEL CROSSMEMBER .

Install the driveshaft. Refer to Removal and Installation or Removal and Installation .

Install exhaust system and adjust free of tension. Refer to [For engine(s) CAUA] Description and Operation or to [For engine(s) CAEB] Description and Operation or to [For engine(s) CALA] Description and Operation .

Fill gear oil in transfer case. Refer to TRANSFER CASE GEAR OIL, FILLING AFTER REPAIR .

REAR FLANGE SHAFT SEAL

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Thrust Plate VW 402
3. Punch VW 409
4. Thrust Disc VW 412
5. Base Block VW 441
6. Thrust Piece T40190

Remove the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED .

Remove the circlip -arrow- on the inside of the housing.

Scheme 32

Note. The circlip secures the flange shaft to the bearing in the housing.

Remove the flange shaft -A- from the center differential housing using the VW 409. To do this, place the housing on the VW 401 and VW 402.

Scheme 33

Note. Hold the flange shaft -A- with one hand so that it does not fall out.

Pry out the seal.

Scheme 34

Note. Place a pry bar -A- underneath to protect the housing.

Coat outer edge of seal with gear oil.

1. Installed position: The open side of the seal faces the housing.

Install the new shaft seal all the way in using the T40190. Do not bend the seal.

Scheme 35

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

Install the flange shaft -A- into the center differential housing using the VW 441 and the VW 412. When doing this, place the housing on the VW 401 and VW 402.

Scheme 36

Note. Install the flange shaft just far enough until it is possible to install the locking ring.

Install the locking ring -arrow- into the groove on the flange shaft.

Install the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED .

Fill gear oil in transfer case. Refer to TRANSFER CASE GEAR OIL, FILLING AFTER REPAIR .

REAR FLANGE SHAFT BALL BEARING

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Thrust Plate VW 402
3. Thrust Disc VW 412
4. Press Tube 2040
5. Tube 60 mm Dia. VW 415 A

Procedure

Remove the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED .

Remove the following: the locking ring from the rear flange shaft -A-, the rear flange shaft and the rear flange shaft seal. Refer to REAR FLANGE SHAFT SEAL .

Scheme 37

Remove the ball bearing locking ring -B-.

Note. The rear flange shaft and the seal for the rear flange shaft -A- are shown installed.

Scheme 38

Scheme 39

1. The shoulder on the VW 415 A -arrow- faces the VW 412.

CENTER DIFFERENTIAL BALL BEARING

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Thrust Plate VW 402
3. Thrust Disc VW 412
4. Arbor 50 mm Dia. VW 432
5. Carrier Bearing Inst. Tool 3350
6. Separating Device 22 to 115 mm Kukko 17/2

Procedure

Remove the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED .

Remove the center differential -1- from the input shaft.

Note. There are different versions of the center differential -1-.

Scheme 40

A - Kukko 17/2

The VW 432 faces the ball bearing.

Scheme 41

Scheme 42

Special tools and workshop equipment required

1. Engine-/Gearbox Jack V.A.G 1383 A
2. Transmission Support T10337
3. Counterhold Tool T10172
4. Adapter T10172/5
5. Oil Collecting and Extracting Device V.A.G 1782
6. Torque Wrench V.A.G 1331

Scheme 43

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Thrust Plate VW 402
3. Punch VW 409
4. Thrust Disc VW 412
5. Base Block VW 441
6. Thrust Piece T40190

Scheme 44

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Thrust Plate VW 402
3. Thrust Disc VW 412
4. Press Tube 2040
5. Tube 60 mm Dia. VW 415 A

Scheme 45

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Thrust Plate VW 402
3. Thrust Disc VW 412
4. Arbor 50 mm Dia. VW 432
5. Carrier Bearing Inst. Tool 3350
6. Separating Device 22 to 115 mm Kukko 17/2

Needle Bearing Drift VW 295

Scheme 46

Pry Lever - Rmv Outside Mirror 80 - 200

Scheme 47

Retainer 3419

Scheme 48

Thrust Piece T10135

Scheme 49

Thrust Piece T10139

Scheme 50

Extractor Lever VW 681

Scheme 51

Slide Hammer-Complete Set VW 771

Scheme 52

See also:
• REPAIR INFORMATION
• CLEAN WORKING CONDITIONS
• TORQUE CONVERTER SHAFT SEAL
• TORQUE CONVERTER
• TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER
• Removal and Installation
• Driveshaft Heat Shield - Tightening Specification
• ATF, CHECKING LEVEL AND CORRECTING
• Removal and Installation
• TUNNEL CROSSMEMBER
• Removal and Installation
• Removal and Installation
• [For engine(s) CALA] Description and Operation
• FRONT FINAL DRIVE OVERVIEW
• CENTER DIFFERENTIAL HOUSING OVERVIEW
• LEFT FLANGE SHAFT SEAL
• FRONT FINAL DRIVE COVER - TIGHTENING SPECIFICATIONS AND SEQUENCE
• RIGHT FLANGE SHAFT SEAL
• RIGHT FLANGE SHAFT
• FRONT FINAL DRIVE COVER O-RING
• SELECTOR SHAFT SEAL
• LEFT FLANGE SHAFT
• CENTER DIFFERENTIAL BALL BEARING
• REAR FLANGE SHAFT BALL BEARING
• CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED
• REAR FLANGE SHAFT SEAL
• CENTER DIFFERENTIAL HOUSING - TIGHTENING SPECIFICATION AND SEQUENCE
• GEAR OIL LEVEL IN FRONT FINAL DRIVE, CHECKING AND FILLING
• GEAR OIL IN FRONT FINAL DRIVE, FILLING AFTER REPAIR
• TRANSFER CASE GEAR OIL, FILLING AFTER REPAIR