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Rear Final Drive 0bd (coupe) Audi A5 I

Axle Shafts 68 illustrations ~5933 words

REAR FINAL DRIVE GEAR OIL, CHECKING

Special tools and workshop equipment required

  1. Catch tray

Remove the sealing plug -arrow- for checking transmission fluid.

Scheme 254

Scheme 254
Scheme 254

The fluid level is correct when the rear final drive is filled up the lower edge of the fluid fill hole.

  1. Transmission fluid specification, refer to «ENGINE CODE, TRANSMISSION ALLOCATION, RATIOS AND CAPACITIES»(/audi/a5/i-2007-2011/remont/differentials-drive-axles/#general-technical-data-rear-final-drive-0bd-coupe) .

Install the screw plug -arrow- and tighten.

Tightening Specifications: 45 Nm

Scheme 255

Scheme 255: REAR FINAL DRIVE ASSEMBLY OVERVIEW
Scheme 255: REAR FINAL DRIVE ASSEMBLY OVERVIEW
  1. Subframe Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/suspension-rear/#rear-suspension-coupe)
  2. Bolt 95 Nm
  3. Bolt 55 Nm
  4. Bolt 55 Nm
  5. Heat Shield
  6. Bolt 20 Nm
  7. Drive Axle Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/suspension-rear/#rear-suspension-coupe)
  8. Rear Final Drive Removing and installing, refer to «REAR FINAL DRIVE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe) Attaching to the assembly stand «REAR FINAL DRIVE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe)
  9. Driveshaft Removing and installing, refer to «DRIVESHAFT BOLTED ON TRANSMISSION SIDE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-bolted-on-transmission-side) and «DRIVESHAFT ATTACHED ON TRANSMISSION SIDE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-attached-on-transmission-side) Removing from the rear final drive and installing, refer to «DRIVESHAFT FROM REAR FINAL DRIVE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-from-rear-final-drive)
  10. Crossmember

ATTACHING THE REAR FINAL DRIVE TO THE ASSEMBLY STAND

Attach the rear final drive to the holding fixture VW 540 using M10 x 40 bolts -arrows-.

Scheme 256

Scheme 256: ATTACHING THE REAR FINAL DRIVE TO THE ASSEMBLY STAND
Scheme 256: ATTACHING THE REAR FINAL DRIVE TO THE ASSEMBLY STAND

DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW

Note. Observe general repair notes COMPONENT DESCRIPTION . The driveshaft cannot be repaired. They can only be removed, installed and adjusted. Always store and transport driveshaft fully extended only. The driveshaft can be bent at the center joint without using force. A hard bending to the stop may cause damage to the center joint or dust boot. If the driveshaft is only detached at the transmission or from rear final drive, it should be tied up or supported at the shaft end. If necessary, it is permitted to bend the driveshaft at the center joint without using force. Mark the position of all the parts before removing them. Install the parts in the same position, otherwise the imbalance can damage the bearing causing a humming noise. Use the counterhold tool Touareg V10 T10172 and adapters T10172/5 to loosen or tighten the driveshaft bolts. After disconnecting driveshaft from rear final drive, an installed balance washer (thick washer between backing plate and internal multi-point bolt) may not be reinstalled. If there are complaints about noise or vibration, make sure there is no tension on the intermediate bearing before replacing the driveshaft.

Scheme 257

Scheme 257: DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW
Scheme 257: DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW
  1. Rear Final Drive Removing and installing, refer to «REAR FINAL DRIVE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe)
  2. Gasket Replace a damaged (bent) gasket. Replace the gasket if the rubber has started to peel. Remove any grease still on the flange and install the gasket. Sides having different color does not influence the installation.
  3. Driveshaft Removing and installing, refer to «DRIVESHAFT BOLTED ON TRANSMISSION SIDE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-bolted-on-transmission-side) Removing from the transmission and installing, refer to «DRIVESHAFT TO TRANSMISSION»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-to-transmission) Removing from the rear final drive and installing, refer to «DRIVESHAFT FROM REAR FINAL DRIVE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-from-rear-final-drive)
  4. Balancing Washer Not present on every vehicle Possibly located between an internal multi-point bolt -5- and a backing plate -6- on the rear final drive If present, this balancing washer must no longer be installed after disconnecting driveshaft from rear final drive.
  5. Bolt Always replace 30 Nm plus an additional 90° turn Self-locking Always clean the threaded holes in the flange shafts (for example, use a thread cutter) On the rear final drive Tightening specification and sequence «DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-bolted-on-transmission-side-assembly-overview) On the transmission
  6. Backing Plate
  7. Intermediate Bearing
  8. Bolt 20 Nm
  9. Drive

Scheme 258

Scheme 258: DRIVESHAFT TO REAR FINAL DRIVE - TIGHTENING SPECIFICATION AND SEQUENCE
Scheme 258: DRIVESHAFT TO REAR FINAL DRIVE - TIGHTENING SPECIFICATION AND SEQUENCE
  1. Always replace the driveshaft bolts -1-.
  2. Counterhold using the T10172 and T10172/5.

Tighten the bolts -1- in 3 steps as follows

StepBoltsTightening Specification/Additional Turn
11Next to the color dots 30 Nm 1)
21The remaining all around 30 Nm
3190° additional turn all around
1) The CV joint will be pushed toward the opposite side reducing the imbalance.

DRIVESHAFT HEAT SHIELD - TIGHTENING SPECIFICATION

Tighten the bolts -arrows- to 24 Nm.

Scheme 259

Scheme 259: DRIVESHAFT HEAT SHIELD - TIGHTENING SPECIFICATION
Scheme 259: DRIVESHAFT HEAT SHIELD - TIGHTENING SPECIFICATION

DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW

Note. Observe general repair notes COMPONENT DESCRIPTION . The attached driveshaft can only be removed from the transmission if it is removed completely. The driveshaft cannot be repaired. They can only be removed, installed and adjusted. Always store and transport driveshaft fully extended only. The driveshaft can be bent at the center joint without using force. A hard bending to the stop may cause damage to the center joint or dust boot. If the driveshaft is only detached from rear final drive, it should be tied up or supported at the shaft end. If necessary, it is permitted to bend the driveshaft at the center joint without using force. Use the counterhold tool Touareg V10T10172 and adapters T10172/5 to loosen or tighten the driveshaft bolts. Always hold the driveshaft horizontal when installing it or removing it from the transmission output shaft. Follow the tightening sequence for attaching the driveshaft bolts to the rear final drive DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

If there are complaints (noise, vibration), do the following before replacing the driveshaft

  1. Make sure the center bearing is free of tension.
  2. Remove the driveshaft bolts on the rear final drive. Tighten the driveshaft following the tightening sequence «DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-mounted-on-transmission-side-assembly-overview) .

Scheme 260

Scheme 260
Scheme 260
  1. Drive
  2. Hose Clamp Replace
  3. Driveshaft Removing and installing, refer to «DRIVESHAFT ATTACHED ON TRANSMISSION SIDE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-attached-on-transmission-side) Removing from the rear final drive and installing, refer to «DRIVESHAFT FROM REAR FINAL DRIVE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-from-rear-final-drive)
  4. Backing Plate
  5. Bolt Always replace 30 Nm plus an additional 90° turn Self-locking Threaded holes in flange shaft at rear final drive must be cleaned of locking compound residue. Use a thread cutter to clean the holes. On the rear final drive Tightening specification and sequence «DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-mounted-on-transmission-side-assembly-overview) On the transmission
  6. Gasket Replace a damaged (bent) gasket. Replace the gasket if the rubber has started to peel. Remove any grease still on the flange and install the gasket. Sides having different color does not influence the installation.
  7. Rear Final Drive Removing and installing, refer to «REAR FINAL DRIVE»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe)
  8. Intermediate Bearing
  9. Bolt 20 Nm

DRIVESHAFT TO REAR FINAL DRIVE - TIGHTENING SPECIFICATION AND SEQUENCE

  1. Always replace the driveshaft bolts -1-.
  2. Counterhold using the T10172 and T10172/5.

Tighten the bolts -1- in 3 steps as follows

StepBoltsTightening Specification/Additional Turn
11Next to the color dots 30 Nm 1)
21The remaining all around 30 Nm
3190° additional turn all around
1) The CV joint will be pushed toward the opposite side reducing the imbalance.

Tighten the bolts -arrows- to 24 Nm.

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Backing Plate for Driveshaft 230 + 90°
Crossmember55
Heat Shield20
Intermediate Bearing Bracket20
Screw Plug45
Subframe 1
55
95
1 For bolt tightening clarification, refer to REAR FINAL DRIVE ASSEMBLY OVERVIEW and see items -2 and 3- 2 Always replace
  1. Always replace the driveshaft bolts -1-.
  2. Counterhold using the counterhold tool Touareg V10T10172 and adapters T10172/5.

Tighten the bolts -1- in 3 steps as follows

StepBoltsTightening Specification/Additional Turn
11Next to the color dots 30 Nm 1)
21The remaining all around 30 Nm
3190° additional turn all around
1) The CV joint will be pushed toward the opposite side reducing the imbalance.

Tighten the bolts -arrows- to 24 Nm.

Special tools and workshop equipment required

  1. Counterhold tool Touareg V10T10172 and adapters T10172/5
  2. Socket XZN 12 T40154
  3. Engine/Transmission Jack V.A.G 1383 A with Universal Transmission Support V.A.G 1359/2

REMOVING

Observe general repair notes COMPONENT DESCRIPTION .

Place the vehicle on a hoist.

Note. Do not bend the decoupling element in the front exhaust pipe more than 10°, otherwise it will get damaged.

Loosen the clamping sleeve(s) -arrows- and disconnect the exhaust system.

Scheme 261

Scheme 261: REMOVING
Scheme 261: REMOVING

Tie the front exhaust pipe(s) to the underbody.

Remove the rear crossmember -1-, if equipped.

Scheme 262

Scheme 262
Scheme 262

Install rear section of the exhaust system -2-. 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 .

Note. A second technician will be needed to help remove the rear section of the exhaust system.

Audi A4 and Audi A5

Remove the heat shield -3- from the body -arrows-.

Continuation for All Vehicles

Check whether there is a marking (color marking) on driveshaft and at flange/driveshaft at rear final drive -arrow A- and -arrow B-.

Scheme 263

Scheme 263
Scheme 263

If one of these markings is no longer visible (for example -arrow A- on the driveshaft), then make a new color marking.

  1. Die marking on the driveshaft -arrow A- and on the rear final drive -arrow B- must line up.

Remove the bolts -1- (quantity: 6) from the rear CV joint.

Use the T10172 with the T10172/5.

Audi A4 and Audi A5

Attach the rear crossmember -C- to the body, if removed earlier.

Scheme 264

Scheme 264
Scheme 264

Place a block of wood -A- (approximately 40 mm tall) on the rear crossmember -C- and secure the driveshaft -B-.

Note. The heat shield under the intermediate bearing supports the driveshaft -B- on the Audi Q5. The driveshaft can be bent at the center joint without using force. A hard bending to the stop may cause damage to the center joint or dust boot.

Continuation for All Vehicles

Remove the bolts from the driveshaft center bearing -arrows-.

Scheme 265

Scheme 265
Scheme 265

Push the driveshaft forward while pulling off the rear final drive.

Tie the driveshaft to the side of the subframe.

Remove the left drive axle heat shield -A- from the crossmember/rear final drive -arrows-.

Scheme 266

Scheme 266
Scheme 266

Remove the left -1- and right -3- drive axles.

Scheme 267

Scheme 267
Scheme 267

Loosen the bolts -2- approximately 3 turns.

Remove the bolt -4-.

Place the V.A.G 1383 A with the V.A.G 1359/2 and a block of wood -A- (approximately 80 mm tall) under the rear final drive.

Scheme 268

Scheme 268
Scheme 268

Note. Make sure the V.A.G 1359/2 is not touching the fuel tank.

Remove the bolts -1- (lower crossmember bolt to the rear final drive) and -2-.

Remove the two upper crossmember bolts -B- to the rear final drive.

Scheme 269

Scheme 269
Scheme 269

Guide the T40154 through the holes in the subframe -A-. Move the final drive to the left or to the right if necessary.

Push the final drive -A- slightly to the front.

Scheme 270

Scheme 270
Scheme 270

Turn the crossmember -B- to the left in direction of -arrow 1- while guiding it past the final drive -arrow 2- and remove it.

Note. A second technician will be needed to continue removing the rear final drive.

A second technician must lift the rear final drive -1- on the right side and push it in direction of -arrow- toward the left side of the vehicle.

Scheme 271

Scheme 271
Scheme 271

Note. The V.A.G 1383 A and the V.A.G 1359/2 are not shown in the upper area I of the illustration.

Guide the right drive axle -5- upward and out of the final drive flange shaft -4-.

Remove the left drive axle -3-.

Secure the rear final drive with a strap -B-.

Scheme 272

Scheme 272
Scheme 272

A - Block of wood

Lower rear final drive completely.

INSTALLING

Installation is in reverse order of removal. Observe the following when doing so

Mount the rear final drive -1- with the V.A.G 1383 A and V.A.G 1359/2 on the subframe -2- in its installed position.

Note. The V.A.G 1383 A and the V.A.G 1359/2 are not shown in the upper area I of the illustration.

Install the left drive axle -3- into the final drive flange shaft.

A second technician must lift the rear final drive -1- on the right side and push it in direction of -arrow- toward the left side of the vehicle.

Insert the right drive axle -5- into the final drive flange shaft -4-.

Push the final drive -A- slightly to the front.

Rotate and install the crossmember -B- in the opposite direction of -arrow 1- while guiding past the final drive -arrow 2-.

Tighten the 4 bolts that connect the crossmember -B- to the rear final drive diagonally to the tightening specification -4- REAR FINAL DRIVE ASSEMBLY OVERVIEW .

Guide the T40154 through the holes in the subframe -A-. Move the final drive to the left or to the right if necessary.

Install the bolts -2- and -4- hand-tight.

Note. The V.A.G 1383 A and the V.A.G 1359/2 are not shown in the illustration.

Tighten the bolt -4- to the tightening specification -3- REAR FINAL DRIVE ASSEMBLY OVERVIEW .

Tighten the bolts -2- to the tightening specification -2- REAR FINAL DRIVE ASSEMBLY OVERVIEW .

Remove the V.A.G 1383 A from under the final drive.

Install the left -1- and right -3- drive axles. Refer to Removal and Installation .

Attach the left drive axle heat shield -A- to the crossmember/rear final drive -arrows- -6- REAR FINAL DRIVE ASSEMBLY OVERVIEW .

Tighten the driveshaft to the rear final drive. Match up the markings and follow the tightening sequence DRIVESHAFT FROM REAR FINAL DRIVE .

Tighten the driveshaft intermediate bearing to the body so that it is free of tension -arrows-. Tightening specification -8- DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

Check axle oil level in rear final drive. Refer to REAR FINAL DRIVE GEAR OIL, CHECKING .

Audi A4 and Audi A5

Attach the heat shield -3- to the body -arrows-.

Continuation for All Vehicles

Install and adjust rear part of exhaust system free of stress. 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 .

Attach the crossmember -1-, if equipped, to the body. Refer to Removal and Installation .

FLANGE SHAFT SEALS, REAR FINAL DRIVE REMOVED

  1. The seals can only be replaced when the rear final drive is removed.

Special tools and workshop equipment required

  1. Needle Bearing Drift VW 295
  2. Puller T10037
  3. Thrust Piece T40110
  4. Thrust Piece T40111
  5. Sealing Grease G 052 128 A1

RIGHT FLANGE SHAFT SEAL

Follow the general repair instructions COMPONENT DESCRIPTION .

Remove rear final drive. Refer to REAR FINAL DRIVE .

Thread T10037 tightly to housing -arrow- and pull out flange shaft.

Scheme 273

Scheme 273: RIGHT FLANGE SHAFT SEAL
Scheme 273: RIGHT FLANGE SHAFT SEAL

Pry out the shaft seal.

Scheme 274

Scheme 274
Scheme 274

Coat the outer circumference of the shaft seal with gear oil.

Scheme 275

Scheme 275
Scheme 275

Fill the space between the sealing and dust lips halfway with sealing grease G 052 128 A1.

Install the new shaft seal all the way without tilting it.

Check the ring for damage before installing the flange shaft. Replace the ring if necessary. Refer to FLANGE SHAFT RING .

Remove the old ring -A- from the groove in the flange shaft using pliers.

Scheme 276

Scheme 276
Scheme 276

B - Protective covers

Install the new ring being careful not to overstretch it.

Drive in flange shaft using VW 295.

Scheme 277

Scheme 277
Scheme 277

Install rear final drive. Refer to REAR FINAL DRIVE .

Check the gear oil in the rear final drive. Refer to REAR FINAL DRIVE GEAR OIL, CHECKING .

LEFT FLANGE SHAFT SEAL

Follow the general repair instructions. Refer to COMPONENT DESCRIPTION .

Remove rear final drive. Refer to REAR FINAL DRIVE .

Thread T10037 tightly to housing -arrow- and pull out flange shaft.

Scheme 278

Scheme 278: LEFT FLANGE SHAFT SEAL
Scheme 278: LEFT FLANGE SHAFT SEAL

Pry out the shaft seal.

Coat the outer circumference of the shaft seal with gear oil.

Fill the space between the sealing and dust lips halfway with sealing grease G 052 128 A1.

Install the new shaft seal all the way without tilting it.

Check the ring for damage before installing the flange shaft. Replace the ring if necessary. Refer to FLANGE SHAFT RING .

Scheme 279

Scheme 279
Scheme 279

Remove the old ring -A- from the groove in the flange shaft using pliers.

B - Protective covers

Install the new ring being careful not to overstretch it.

Drive in flange shaft using VW 295.

Install rear final drive. Refer to REAR FINAL DRIVE .

Check the gear oil in the rear final drive. Refer to REAR FINAL DRIVE GEAR OIL, CHECKING .

FLANGE SHAFT RING

Special tools and workshop equipment required

  1. Thrust Plate VW 401
  2. Thrust Plate VW 402
  3. Punch VW 407
  4. Sleeve 32 - 119
  5. Thrust Pad 3062
  6. 3- Separating Device 22 to 115 mm, for example Kukko 17/2

Scheme 280

Scheme 280
Scheme 280

A - Separating tool 22 to 115 mm, for example Kukko 17/2

Scheme 281

Scheme 281
Scheme 281
  1. Installed position of the ring -A- : the indentation in the ring faces the 32 - 119.

FLANGE AND DRIVESHAFT SEALS, REAR FINAL DRIVE REMOVED

  1. It is necessary to install the old flange/driveshaft.
  2. If the flange/driveshaft is also being removed. Refer to «FLANGE/DRIVESHAFT AND SEAL WITH REAR FINAL DRIVE REMOVED»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__flangedriveshaft-and-seal-with-rear-final) .

Special tools and workshop equipment required

  1. Puller VW 391
  2. Slide Hammer - Complete Set VW 771
  3. Pulling hook VW 771/37
  4. Thrust Piece T40112
  5. Retainer 3028
  6. Seal Driver-Frt Wheel Bearing 3143
  7. Adapter T10235
  8. Friction Meter VAS 6222
  9. Inductive Heat Unit VAS 6414
  10. Sealing grease G 052 128 A1
  11. Locking fluid AMV 185 101 A1
  12. Three M8 x 25 bolts
  13. 2 bolts M10 x 40
  1. The flange shaft/driveshaft seal can be replaced only when the rear final drive is removed.

Observe general repair notes COMPONENT DESCRIPTION .

Remove rear final drive. Refer to REAR FINAL DRIVE .

Attach the rear final drive to the holding fixture VW 540 using M10 x 40 bolts -arrows-.

Measure the friction torque before loosening the pinion nuts.

Scheme 282

Scheme 282
Scheme 282

Write down this value.

CAUTIONIf, during the repair, the flange/driveshaft must be replaced, then this measured value must be adjusted again. Refer to FLANGE/DRIVESHAFT AND SEAL WITH REAR FINAL DRIVE REMOVED .

Mark the location of the pinion nut on the pinion -arrow-.

Scheme 283

Scheme 283
Scheme 283

Determining Dimensions a and b

Scheme 284

Scheme 284
Scheme 284
  1. Distance between the flange and the pinon = dimension -a
  2. Distance between the flange and the pinon nut = dimension -b

Write down the dimensions.

Attach the 3028 to the flange/driveshaft with the bolts -A-.

Scheme 285

Scheme 285
Scheme 285

Attach the T10235 in the threaded hole under the flange/driveshaft.

Loosen the pinion nut. The 3028 will be supported by the T10235 -arrow-.

Count the number of turns when removing the pinion nut and write this number down.

A- three M8 x 25 bolts

B- 32 mm socket

C- bar

Mark the location of the flange/driveshaft -arrow A- to the pinion -arrow B-.

Scheme 286

Scheme 286
Scheme 286

Place the drip tray underneath.

Install the VW 391 with two M8 x 25 bolts -arrows-.

Scheme 287

Scheme 287
Scheme 287

Remove the flange/driveshaft.

Remove the shaft seal.

Scheme 288

Scheme 288
Scheme 288

Clean the thread on the pinion.

Installation is in reverse order of removal. Observe the following when doing so

Coat the outer circumference of the shaft seal with gear oil.

Fill the space between the sealing and dust lips halfway with sealing grease G 052 128 A1.

Install the new shaft seal all the way without tilting it.

Scheme 289

Scheme 289: INSTALLING
Scheme 289: INSTALLING

Warm the flange/driveshaft to approximately 80 °C (176 °F) with an VAS 6414.

Line up the markings on the flange/driveshaft -arrow A- and pinion -arrow B-.

Install the flange/driveshaft.

Scheme 290

Scheme 290
Scheme 290

Install the old pinion nut with locking fluid AMV 185 101 A1.

Attach the 3028 to the flange/driveshaft with the bolts -A-.

Scheme 291

Scheme 291
Scheme 291

The 3028 must be supported by the housing brace -arrow- when tightening the pinion nut.

A- three M8 x 25 bolts

B- 32 mm socket

C- bar

Tighten the pinion the number of turns noted earlier when it was being removed at the marked location -arrow-.

Checking dimensions a and b

  1. Measurement deviation: ± 0.2 mm

Install rear final drive. Refer to REAR FINAL DRIVE .

Check the gear oil in the rear final drive. Refer to REAR FINAL DRIVE GEAR OIL, CHECKING .

FLANGE/DRIVESHAFT AND SEAL WITH REAR FINAL DRIVE REMOVED

Special tools and workshop equipment required

  1. Puller VW 391
  2. Slide Hammer - Complete Set VW 771
  3. Pulling hook VW 771/37
  4. Thrust Piece T40112
  5. Retainer 3028
  6. Seal Driver-Frt Wheel Bearing 3143
  7. Adapter T10235
  8. Friction Meter VAS 6222
  9. Inductive Heat Unit VAS 6414
  10. Sealing Grease G 052 128 A1
  11. Locking Fluid AMV 185 101 A1
  12. Three M8 x 25 bolts
  13. 2 bolts M10 x 40

Follow the General Repair Instructions. Refer to COMPONENT DESCRIPTION .

Remove rear final drive. Refer to REAR FINAL DRIVE .

Attach the rear final drive to the holding fixture VW 540 using M10 x 40 bolts -arrows-.

Measure the friction torque before loosening the pinion nuts.

Write down this value.

CAUTIONThe measured value must be adjusted again after replacing the shaft seal.

Attach the 3028 to the flange/driveshaft with the bolts -A-.

Attach the T10235 in the threaded hole under the flange/driveshaft.

Loosen the pinion nut. The 3028 will be supported by the T10235 -arrow-.

A- three M8 x 25 bolts

B- 32 mm socket

C- bar

Install the VW 391 with two M8 x 25 bolts -arrows-.

Remove the flange/driveshaft.

Remove the shaft seal.

Clean the thread on the pinion.

Coat the outer circumference of the shaft seal with gear oil.

Fill the space between the sealing and dust lips halfway with sealing grease G 052 128 A1.

Install the new shaft seal all the way without tilting it.

Warm the flange/driveshaft to approximately 80 °C (176 °F) with an VAS 6414.

Install the new flange/driveshaft.

Coat the thread on the new nut with locking fluid AMV 185 101 A1.

Attach the 3028 to the flange/driveshaft with the bolts -A-.

The 3028 must be supported by the housing brace -arrow- when tightening the pinion nut.

A- three M8 x 25 bolts

B- 32 mm socket

C- bar

CAUTIONSlowly increase the torque and read the friction torque several times. Do not exceed the friction torque measured before removal otherwise the rear final drive will have to be replaced.

Tighten the new pinion nut just far enough until the friction torque, measured prior to removal, is reached.

Install rear final drive. Refer to REAR FINAL DRIVE .

Check the gear oil in the rear final drive. Refer to REAR FINAL DRIVE GEAR OIL, CHECKING .

FLANGE/DRIVESHAFT SEAL

Special tools and workshop equipment required

  1. Thrust Plate VW 402
  2. Punch VW 407
  3. Thrust Disc VW 412
  4. Sleeve 40 - 20
  5. 3- Separating Device 22 to 75 mm, for example Kukko 17/1

Scheme 292

Scheme 292
Scheme 292

A - Separating tool 22 to 115 mm, for example Kukko 17/2

Scheme 293

Scheme 293
Scheme 293
  1. Installed position of the ring -A- : the indentation in the ring faces the 40 - 20.

DRIVESHAFT BOLTED ON TRANSMISSION SIDE

Special tools and workshop equipment required

  1. Alignment Fixture-4W Dr. Shaft 3139
  2. Counterhold Tool Touareg V10T10172 and Adapters T10172/5
  3. Engine/Transmission Jack V.A.G 1383 A with Universal Mount V.A.G 1359/2
  4. High temperature grease G 000 633
  1. See notes, refer to «DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-bolted-on-transmission-side-assembly-overview)
  2. Working on the driveshaft should only be performed with the vehicle on a two-column shop hoist.

Note. Do not bend the decoupling element in the front exhaust pipe more than 10°, otherwise it will get damaged.

Loosen the clamping sleeve(s) -arrows- and disconnect the exhaust system.

Tie the front exhaust pipe(s) to the underbody.

Install rear section of the exhaust system -2-. 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 .

Note. A second technician will be needed to help remove the rear section of the exhaust system.

Audi A4 and Audi A5

Remove the crossmember -1-.

Remove the heat shield -3- -arrows-.

Audi Q5

Remove the front -2- and rear -3- crossmembers.

Scheme 294

Scheme 294
Scheme 294

Remove the heat shield -1- from the body.

Continuation for All Vehicles

Remove the heat shield -A- from the transmission -arrows-, if equipped.

Scheme 295

Scheme 295
Scheme 295

Check whether there is a marking (color marking) on driveshaft and at flange/driveshaft at rear final drive -arrow A- and -arrow B-.

If one of these markings is no longer visible (for example -arrow A- on the driveshaft), then make a new color marking.

  1. Die marking on the driveshaft -arrow A- and on the rear final drive -arrow B- must line up.

Attach the 3139 and tighten the plastic nuts.

Scheme 296

Scheme 296
Scheme 296

Note. Never lay the assembly tool on the balance plates.

Remove the bolts -arrows- for intermediate bearing.

Scheme 297

Scheme 297
Scheme 297

Remove the bolts connecting the driveshaft to the transmission using the T10172 and T10172/5.

Scheme 298

Scheme 298
Scheme 298

Remove driveshaft from transmission and support it using V.A.G 1383 A.

Remove the bolts -1- (quantity: 6) from the rear CV joint.

Use the T10172 and T10172/5.

Remove driveshaft.

Note. Always store and transport a driveshaft fully extended only.

Installation is in reverse order of removal. Observe the following when doing so

  1. Remove any old or dried-up high temperature grease from the CV joints and the driveshaft flanges. Fill with the exact same amount of high temperature grease G 000 633.
  2. Clean any locking fluid still inside the threaded holes in the flange shafts for the transmission driveshaft and rear final drive. Use a thread cutter to clean the holes. Otherwise the bolts could break off when being installed.
  3. After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and a bolt may not be reinstalled.
  4. Always replace (self-locking) securing bolts for driveshaft.
  5. Note installation position of driveshaft: Center CV joint is located behind intermediate bearing in direction facing the rear final drive.
  6. Check the driveshaft seal on the rear final drive for damage (bent or the rubber has started to peel) Replace a damaged gasket.

Install the driveshaft. Pay attention to the installed position on the rear final drive

  1. Die markings on the driveshaft -arrow A- and on the rear final drive -arrow B- must line up.
  2. Maximum difference between the markings: 30°.

Install the bolts all he way in by hand but to do not tighten them.

Install the bolts -arrows- just far enough so that the intermediate bearing can still be moved.

Tighten the rear bolts -1- on the driveshaft. Follow the tightening sequence DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW

Tighten the front bolts on the driveshaft. Tightening specification -5- DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

Remove 3139.

Tighten bolts of intermediate bearing for driveshaft onto body tightening specification -8- DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

Attach the heat shield -A- (if equipped) to the transmission -arrows-. Tightening specification DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW

Install the heat shield -1-.

Remove the front -2- and rear -3- crossmembers, if equipped. Refer to Removal and Installation .

Install and adjust exhaust system free of stress. 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 .

DRIVESHAFT TO TRANSMISSION

Special tools and workshop equipment required

  1. Counterhold Tool Touareg V10T10172 and Adapters T10172/5
  2. High temperature grease G 000 633
  1. See notes, refer to «DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-bolted-on-transmission-side-assembly-overview)
  2. Working on the driveshaft should only be performed with the vehicle on a two-column shop hoist.

Note. Do not bend the decoupling element in the front exhaust pipe more than 10°, otherwise it will get damaged.

Loosen the clamping sleeve(s) -arrows- and disconnect the exhaust system.

Tie the front exhaust pipe(s) to the underbody.

Remove the heat shield -A- from the transmission -arrows-, if equipped.

Remove the bolts connecting the driveshaft to the transmission using the T10172 and T10172/5.

Tie the driveshaft to the underbody.

Installation is in the reverse order of removal. Observe the following when doing so

  1. Remove any old or dried-up high temperature grease from the CV joint and the driveshaft flange. Fill with the exact same amount of high temperature grease G 000 633.
  2. Threaded holes in flange shaft on the transmission must be cleaned of locking compound residue. Use a thread cutter to clean the holes. Otherwise the bolts could break off when being installed.
  3. Always replace (self-locking) securing bolts for driveshaft.

Check the driveshaft seal on the transmission flange for damage and replace if necessary.

Install the driveshaft and install the CV joint bolts.

Tighten the front bolts on the driveshaft. Tightening specification -5- DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

  1. Use the T10172 with the T10172/5.

Attach the heat shield -A- (if equipped) to the transmission -arrows-. Tightening specification DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

Assemble the exhaust system and then align it 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 .

DRIVESHAFT FROM REAR FINAL DRIVE

Special tools and workshop equipment required

  1. Counterhold Tool Touareg V10T10172 and Adapters T10172/5
  2. High temperature grease G 000 633
  1. See notes, refer to «DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-bolted-on-transmission-side-assembly-overview)
  2. Working on the driveshaft should only be performed with the vehicle on a two-column workshop hoist.

Note. Do not bend the decoupling element in the front exhaust pipe more than 10°, otherwise it will get damaged.

Loosen the clamping sleeve(s) -arrows- and disconnect the exhaust system.

Tie the front exhaust pipe(s) to the underbody.

Note. A second technician will be needed to help remove the rear section of the exhaust system.

Remove rear portion of exhaust system. 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 .

Check whether there is a marking (color marking) on driveshaft and at flange/driveshaft at rear final drive -arrow A- and -arrow B-.

If one of these markings is no longer visible (for example -arrow A- on the driveshaft), then make a new color marking.

  1. Die marking on the driveshaft -arrow A- and on the rear final drive -arrow B- must line up.

Remove the bolts -1- (quantity: 6) from the rear CV joint.

Use the T10172 with the T10172/5.

Remove the driveshaft from the rear final drive and tie it to the subframe.

Installation is in the reverse order of removal. Observe the following when doing so

  1. Remove any old or dried-up high temperature grease from the CV joint and the driveshaft flange. Fill with the exact same amount of high temperature grease G 000 633.
  2. Threaded holes in flange shaft at rear final drive must be cleaned of locking compound residue. Use a thread cutter to clean the holes. Otherwise the bolts could break off when being installed.
  3. After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and a bolt may not be reinstalled.
  4. Always replace (self-locking) securing bolts for driveshaft.
  5. Check the driveshaft seal on the rear final drive for damage (bent or the rubber has started to peel) Replace a damaged gasket.

Position the driveshaft on the rear final drive paying attention to the installed position

  1. Die markings on the driveshaft -arrow A- and on the rear final drive -arrow B- must line up.
  2. Maximum difference between the markings: 30°.

Install and tighten the driveshaft bolts -1-. Follow the tightening sequence DRIVESHAFT BOLTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW

Install rear section of the exhaust system. 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 .

DRIVESHAFT ATTACHED ON TRANSMISSION SIDE

Special tools and workshop equipment required

  1. VAS 6199 VW 785/1 B
  2. Counterhold Tool Touareg V10 T10172
  3. Adapter T10172/5
  4. Locking Pliers VAS 6199
  5. High temperature grease G 000 633

Note. The attached driveshaft can only be removed from the transmission if it is removed completely. Working on the driveshaft should only be performed with the vehicle on a two-column shop hoist. The driveshaft can be bent at the center joint without using force. A hard bend to the stop may cause damage to the center joint or dust boot. The driveshaft must always be tied up or supported by the end of the shaft. Always hold the driveshaft horizontal when installing it or removing it from the transmission output shaft.

CAUTIONDanger of causing damage to the decoupling element. Never bend the decoupling element more than 10°. Never load the decoupling element. Do not damage the wire mesh on the decoupling element.

Loosen the clamping sleeve(s) -arrows- and disconnect the exhaust system.

Tie the front exhaust pipe(s) to the underbody.

Remove the bolts -arrows- and remove the driveshaft heat shield -1-, if equipped.

Cut the hose clamp -1- for the driveshaft boot and remove it.

Scheme 299

Scheme 299
Scheme 299

Note. Ignore -2-.

Remove the front -2- and rear -3- crossmembers, if equipped.

Remove the heat shield -1-.

Lower the exhaust system rear section near the front and secure it using the VW 785/1 B as illustrated.

Scheme 300

Scheme 300
Scheme 300

Check whether there is a marking (color marking) on driveshaft and at flange/driveshaft at rear final drive -arrow A- and -arrow B-.

If one of these markings is no longer visible, then make a new color marking.

  1. Die markings on the driveshaft -arrow A- and on the rear final drive -arrow B- must line up.

Remove the driveshaft bolts -1- on the rear final drive.

Counterhold using the T10172 and T10172/5.

Remove the bolts -arrows- from the driveshaft center bearing.

Lower the rear driveshaft at the fuel tank and at the subframe and remove it from the transmission.

  1. Tightening specifications, refer to «DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-mounted-on-transmission-side-assembly-overview) and «DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/axle-shafts/#rear-final-drive-0bd-coupe__driveshaft-mounted-on-transmission-side-assembly-overview) .

Note. Remove old and dry high-temperature grease from CV joint and flange for driveshaft. Fill with the exact same amount of high temperature grease G 000 633. Threaded holes in flange shaft at rear final drive must be cleaned of locking compound residue. Use a thread cutter to clean the holes. Otherwise the bolts could break off when being installed. Replace the self-locking bolts. Replace the hose clamp for the driveshaft rubber boot. Check the driveshaft seal on the rear final drive for damage (bent or the rubber has started to peel) Replace a damaged gasket. Wipe off the splines on the transmission output shaft with a towel before attaching it to the driveshaft. Do not grease the splines.

First attach the driveshaft to the transmission.

  1. Maximum bend angle: 10°.
  2. After installing the driveshaft after approximately 50 mm, turn the driveshaft slightly to make sure the splines on the transmission output shaft mesh with the splines on the driveshaft.
  3. Push the driveshaft all the way onto the splines on the transmission output shaft.

Install the bolts -arrows- just far enough so that the intermediate bearing can still be moved.

Position the driveshaft on the rear final drive paying attention to the installed position

  1. Die markings on the driveshaft -arrow A- and on the rear final drive -arrow B- must line up.
  2. Maximum difference between the markings: 30°.

Install all the way in by hand, but do not tighten.

Align the clamp -1- for the driveshaft boot with the mounting points -2- and then tighten is using VAS 6199.

Note. Pushing the driveshaft back just a little makes it easier to use the locking pliers.

Tighten the driveshaft bolts -1-. Follow the tightening sequence DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

Attach the driveshaft center bearing to the body making sure it is free of tension. Tightening specification -5- DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

Install in reverse order of removal. Be sure to note the following

Attach the heat shield -A- to the transmission -arrows-. Tightening specification DRIVESHAFT MOUNTED ON TRANSMISSION-SIDE ASSEMBLY OVERVIEW .

Install the heat shield -1-. Refer to Removal and Installation .

Remove the front -2- and rear -3- crossmembers, if equipped. Refer to Removal and Installation .

Install the exhaust system and adjust it so that it is 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 .

Scheme 301

Scheme 301: SPECIAL TOOLS
Scheme 301: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Puller VW 391
  2. Slide Hammer - Complete Set VW 771
  3. Pulling hook VW 771/37
  4. Thrust Piece T40112
  5. Retainer 3028
  6. Seal Driver-Frt Wheel Bearing 3143

Special tools and workshop equipment required

Scheme 302

Scheme 302
Scheme 302

Scheme 303

Scheme 303
Scheme 303

Scheme 304

Scheme 304
Scheme 304

Scheme 305

Scheme 305
Scheme 305

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Scheme 306
Scheme 306

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Scheme 308
Scheme 308

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Scheme 311

Scheme 311
Scheme 311

Scheme 312

Scheme 312
Scheme 312

Scheme 313

Scheme 313
Scheme 313

Scheme 314

Scheme 314
Scheme 314

Scheme 315

Scheme 315
Scheme 315

Scheme 316

Scheme 316
Scheme 316

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Scheme 317

Scheme 318

Scheme 318
Scheme 318

Scheme 319

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Scheme 319

Scheme 320

Scheme 320
Scheme 320

Scheme 321

Scheme 321
Scheme 321
  1. Counterhold tool Touareg V10T10172 and adapters T10172/5
  2. Socket XZN 12 T40154
  3. Engine/Transmission Jack V.A.G 1383 A with Universal Transmission Support V.A.G 1359/2
  4. Needle Bearing Drift VW 295
  5. Puller T10037
  6. Thrust Piece T40110
  7. Thrust Piece T40111
  8. Thrust Plate VW 401
  9. Thrust Plate VW 402
  10. Punch VW 407
  11. Sleeve 32 - 119
  12. Thrust Pad 3062
  13. 3- Separating Device 22 to 115 mm, for example Kukko 17/2
  14. 3- Separating Device 22 to 75 mm, for example Kukko 17/1
  15. Adapter T10235
  16. Friction Meter VAS 6222
  17. Punch VW 407
  18. Thrust Disc VW 412
  19. Sleeve 40 - 20
  20. Alignment Fixture-4W Dr. Shaft 3139
  21. Counterhold Tool Touareg V10T10172 and Adapters T10172/5
  22. Engine/Transmission Jack V.A.G 1383 A with Universal Mount V.A.G 1359/2
  23. VAS 6199 VW 785/1 B
  24. Locking Pliers VAS 6199
  25. Inductive Heat Unit VAS 6414

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