Rear Final Drive 01r Audi S6 C6

Rear final drive identification

The 01R final drive unit is used with the following transmissions

1. 6 Spd. Manual Transmission 02X
2. 6 Spd. Manual Transmission 0A3
3. 6 Spd. Automatic Transmission 09E All Wheel Drive
4. 6 Spd. Automatic Transmission 09L All Wheel Drive

Allocation --> Code letters, assembly allocation, ratios

When installing a new rear final drive unit, it is important to verify the engine code of the vehicle as well as the code letters of the rear final drive. This is necessary to ensure that the correct version is installed.

Scheme 1

Code letters and date of construction - arrow 1

Final drive 01R - arrow2

Scheme 2

Final drive 01R - arrow2

Scheme 3

Further data can be ignored.

Code letters, assembly allocation, ratios

Drivetrain overview

1. Illustrated with 6 Spd. Manual Transmission 0A3 All Wheel Drive

Designation

Note. Arrows point in direction of travel

Scheme 4

1 - Engine

2 - Clutch

3 - Manual transmission

4 - Input shaft (main shaft)

5 - Front differential

6 - Front drive pinion (output shaft)

7 - Hollow shaft

8 - Torsen differential

9 - Driveshaft

10 - Rear drive pinion

11 - Rear differential

Gear ratios

Note. Arrows point in direction of travel

I - 1st gear

II - 2nd gear

III - 3rd gear

IV - 4th gear

V - 5th gear

VI - 6th gear

R - Reverse gear

A1 - Front final drive

A2 - Rear final drive

General repair instructions

To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools is essential. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the article, are summarized here under the topic "Components" --> Components . They apply to this article.

Vehicle jack mode (vehicles with air suspension)

Activate the vehicle jack mode before lifting the vehicle on a frame contact hoist (i.e. when there is no weight on the wheels) --> 43 - SELF LEVELING SUSPENSION .

1. Allocate bolts and other components according to final drive code letters .
2. When installing a new rear final drive unit, check the oil level in the rear final drive and top up if necessary --> «Gear oil in rear final drive, checking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
3. Filling quantity and specification --> «Code letters, assembly allocation, ratios»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__code-letters-assembly-allocation-ratios)
4. When assembling mounting brackets as well as other waxed components the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.

1. Carefully clean all joints and adjacent areas before disconnecting.

O-rings, oil seals, gaskets

1. Always replace O-rings, seals and gaskets.
2. After removing gaskets, examine contact surface on housing/shaft for burrs resulting from removal or for other signs of damage.
3. Thoroughly clean housing joint surfaces before assembling.

Scheme 5

1. Lightly lubricate outer edge and fill space between sealing lips - arrow - halfway with grease G052128A1 .
2. Open sides of oil seals face fluid side.
3. Lightly oil O-rings before installing; this prevents the rings being crushed when inserting.
4. After replacing seals and gaskets, check and, if necessary, top up oil level in final drive --> «Gear oil in rear final drive, checking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

Locking elements

1. Do not overstretch circlips.
2. Always replace circlips which have been damaged or over-tensioned.
3. Circlips must be properly seated in the base of the groove.

Scheme 6

1. Replace spring pins. Installation position: Slit - A - should be in line with the line of force - arrow -.

Bolts and nuts

1. Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
2. Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.
3. The tightening torques stated apply to unlubricated bolts and nuts.
4. Replace self-locking bolts and nuts.

1. Clean threads of bolts that were applied with locking fluid using a wire brush (does not apply to driveshaft bolts: these must be replaced). Apply locking fluid AMV185101A1 before reinstalling.
2. Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

Bearings

1. Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
2. Install new tapered roller bearing as supplied and do not use additional oil.
3. Taper roller bearings fitted to one shaft must be replaced as a set. Use same make of bearings.
4. Lubricate bearing seats lightly with gear oil before pressing bearings onto shafts.

1. Lubricate bearing seats lightly with gear oil before installing bearings and outer bearing races into final drive housing.
2. Heat inner races to approx. 100° C before installing.
3. Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.

Adjustment shims

1. Use a micrometer to measure the shims at several points. Varying tolerances make it possible to measure the required shim thickness exactly.
2. Inspect for burrs and signs of damage.
3. Do not install shims which are damaged or not in perfect condition.

Servicing driveshaft - component overview

Note. Refer to general repair instructions --> General repair instructions . No repair work can be carried out on the driveshaft with the exception of removing, installing and adjusting. Always store and transport the driveshaft in the extended position. The driveshaft can be bent as far as the end stop of the center joint provided that no force is used. Bending the joint forcibly to the end stop can damage the center joint and/or the protective boot. If the drive shaft is separated only from the transmission or the rear final drive, the drive shaft must be tied up by the CV joints or otherwise supported. If necessary, the driveshaft can be bent as far as the end stop of the center joint provided that no force is used. Before removing, mark the positions of all parts in relation to each other. Re-install in the same position otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises. After detaching the driveshaft from the rear final drive, the balance disc (thick washer) that may be fitted between the lock plate and the socket head bolt must not be re-installed. If problems occur (noise or vibration), ensure that the centre bearing is free of stress and check the radial runout of the driveshaft flange at the rear final drive before replacing the driveshaft --> Radial runout at driveshaft flange on rear final drive, measuring and marking

Scheme 7

1 - Rear final drive

1. Removing and installing --> «Rear final drive, removing and installing - overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

2 - Gasket

1. Replace
2. Pull off protective foil
3. Clean flange shaft and glue on gasket

3 - Driveshaft

1. Removing and installing --> «Driveshaft, removing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__driveshaft-removing)

4 - Balance disc

1. Not fitted on all vehicles
2. If fitted, balance disc must not be re-installed when driveshaft has been detached from rear final drive.

5 - Hex socket head bolt, 55Nm

1. Self-locking
2. Always replace
3. The threaded holes for the bolts in the flange shafts must always be cleaned. (e. g. with a thread tap)

6 - Lock plate

7 - Center bearing

8 - Bolt, 25 Nm

9 - Transmission

Driveshaft, removing

Special tools, testers and auxiliary items required

Scheme 8

1. Alignment fixture 3139

Scheme 9

1. Engine/transmission jack V.A.G1383A with universal transmission adapter V.A.G1359/2
2. Refer to notes --> «Servicing driveshaft - component overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
3. A twin post vehicle hoist should be used when working on the driveshaft.

Scheme 10

1. Remove rear tunnel brace - 1 -.
2. Remove rear section of exhaust system - 2 - behind clamps --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281364-S12921374702008031100000) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH or --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK.
3. Remove heat shield - 3 - from vehicle underbody - arrows -.

Scheme 11

1. Remove bolts securing front exhaust pipes - 1 - and - 2 -.

Scheme 12

1. Detach guard plate - A - from transmission - arrows -.

Scheme 13

1. Check whether there is a marking (colored marking) on driveshaft and at flange/driveshaft at rear final drive.
2. If this marking is not present, then mark in color the position of driveshaft flange - arrow A - to rear final drive - arrow B -.

Scheme 14

1. Attach alignment fixture 3139 and tighten plastic nuts.

Note. Never fit assembly appliance onto balance plates.

Scheme 15

1. Remove bolts - arrows - securing center bearing.

Scheme 16

1. Screw hex boltM10x10010.9 - 3 - into rear final drive.
2. To loosen bolts - 1 - for driveshaft at front and rear, counterhold using a lever - 2 -.
3. Remove securing bolts on CV joint at gearbox end, detach driveshaft and support with engine/gearbox jack V.A.G1383A.
4. Remove securing bolts on rear CV joint and take out driveshaft.

Note. Always transport and store driveshaft in extended position.

Driveshaft, installing

Installation is performed in the reverse order of removal. Pay attention to the following

1. Remove old, dried-out high-temperature grease from constant velocity joints and driveshaft flanges. Put in exactly the same quantity of fresh high-temperature grease G 000 633.
2. Always remove any remaining locking fluid from thread bores in drive flanges for transmission driveshaft and for rear final drive. Cleaning can be performed with a thread tap. Otherwise, the securing bolts can shear while screwing in.
3. After removal of the drive shaft from the rear final drive, do not reinstall additional balance washer (thicker washer) that may be between washer and bolt head.
4. Always replace securing bolts for driveshaft (self-locking bolts).

1. Note correct position of driveshaft: The central CV joint is located behind the center bearing and towards the rear final drive.

1. Make sure that the markings on flange for driveshaft - arrow A - and for transmission/rear final drive - arrow B - line up.
2. If a new driveshaft is installed and the factory marking on the rear final drive flange is no longer visible, check radial runout at flange/driveshaft --> «Radial runout at driveshaft flange on rear final drive, measuring and marking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) and adjust color marking at new driveshaft to new marking at flange/driveshaft.

1. Replace seals for driveshaft at transmission/rear final drive flange. Clean sealing surfaces and glue on new gaskets.
2. Install driveshaft and fit bolts for constant velocity joints.

1. Screw in securing bolts - arrows - so that center bearing can still be moved.

1. Screw hex boltM10x10010.9 - 3 - into rear final drive.
2. Tighten bolts - 1 - at front and rear ends of driveshaft to specified torque. (Counterhold with lever - 2 -.)
3. Remove Alignment fixture 3139.

Scheme 17

1. Secure center driveshaft bearing to body so it is free of stress and tighten to specified torque. The centralizing lugs on the center bearing mounting must fit in the locating holes - arrows -.

1. Secure guard plate - A - to transmission - arrows -.

1. Install heat shield - A - to underbody of vehicle - arrows -.
2. Secure both front exhaust pipes and install rear section of exhaust system - 2 - --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281364-S12921374702008031100000) or --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS .
3. Secure rear tunnel brace - 1 -.

Torque specifications

Driveshaft, separating from rear final drive

1. Refer to notes --> «Servicing driveshaft - component overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
2. A twin post vehicle hoist should be used when working on the driveshaft.

Scheme 18

1. Release clamps - 1 - and - 2 - and remove rear section of exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281364-S12921374702008031100000) or --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS .

1. Check whether there is a marking (colored marking) on driveshaft and at flange/driveshaft at rear final drive.
2. If this marking is not present, then mark in color the position of driveshaft flange - arrow A - to rear final drive - arrow B -.

1. Screw hex boltM10x10010.9 - 3 - into rear final drive.
2. Counterhold driveshaft with a suitable lever - 2 - and unscrew bolts - 1 - (6x).

Scheme 19

1. Disconnect driveshaft from rear final drive and tie up - arrow -.

Driveshaft, securing to rear final drive

Installation is performed in the reverse order of removal. Pay attention to the following

1. Remove old, dried-out high-temperature grease from constant velocity joints and driveshaft flanges. Put in exactly the same quantity of fresh high-temperature grease G 000 633.
2. The threads in the flange shaft rear final drive must be cleaned of locking fluid residue. Cleaning can be performed with a thread tap. Otherwise, the securing bolts can shear while screwing in.
3. After removal of the drive shaft from the rear final drive, do not reinstall additional balance washer (thicker washer) that may be between washer and bolt head.
4. Always replace securing bolts for driveshaft (self-locking bolts).

1. Replace the gasket for driveshaft at flange for rear final drive. Clean sealing surface and glue on new gasket.

1. Make sure that the markings on the driveshaft flange - arrow A - and the rear final drive - arrow B - are aligned.
2. Install driveshaft and fit bolts for constant velocity joints.

1. Screw hex boltM10x10010.9 - 3 - into rear final drive.
2. Tighten bolts - 1 - on driveshaft to specified torque. (Counterhold with lever - 2 -.)
3. Install rear section of exhaust system. --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281364-S12921374702008031100000) or --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS

Radial runout at driveshaft flange on rear final drive, measuring and marking

Special tools, testers and auxiliary items required

Scheme 20

1. Dial gauge holder VW387
2. Dial gauge
3. Bolt M10x30

Note. Always measure radial runout if flange has been removed. Remove old paint marking and make new marking. If a new driveshaft is to be installed and the factory colored mark on the rear final drive flange is no longer visible, the position of the maximum runout (corresponds to the maximum distance from the rotational axis) must be determined and marked with a colored dot. Align this colored dot with colored dot on driveshaft --> Driveshaft, installing . Radial runout can be measured with rear final drive installed.

1. Unbolt driveshaft from rear final drive --> «Driveshaft, separating from rear final drive»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__driveshaft-separating-from-rear-final-drive) .

Scheme 21

1. Attach dial indicator bracket to rear final drive.
2. Set dial indicator tip on ground diameter - arrow - in drive shaft flange and zero gauge with 1 mm of preload.
3. Rotate both rear wheels simultaneously in one direction and thereby turn flange through one complete rotation.
4. Make a paint marking at the point of greatest radial runout on the outside of the flange (greatest distance from axis of rotation).

1. Then remove the previous marking from the flange.

1. When installing driveshaft, markings on flange for driveshaft - arrow A - and for rear final drive - arrow B - must then line up.
2. Install driveshaft.

Gear oil in rear final drive, checking

Special tools, testers and auxiliary items required

Scheme 22

1. Drip tray V.A.G1306

Scheme 23

1. Torque wrench V.A.G1331
2. Place drip tray V.A.G1306 underneath.

Scheme 24

1. Unscrew sealing plug for checking transmission fluid - arrow -.
2. The oil level is correct when the rear final drive is filled to the lower edge of the filler hole.
3. Transmission oil specification --> «Code letters, assembly allocation, ratios»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__code-letters-assembly-allocation-ratios) .
4. Top up oil to lower edge of filler hole.

Scheme 25

1 - Subframe

1. Removing and installing --> «42 - REAR SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

2 - Hex bolt

3 - Bolt, 40 Nm

1. Secures final drive support to subframe

4 - Allen head bolt, 40Nm

5 - Washer

6 - Nut, 55 Nm

7 - Rear cross member

8 - Rear final drive

1. Removing and installing --> «Rear final drive, removing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__rear-final-drive-removing)

9 - Drive axle

1. Removing and installing --> «42 - REAR SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

10 - Shield

11 - Allen head bolt, 25Nm

12 - Final drive support

13 - Allen head bolt, 40Nm

Rear final drive, removing

Special tools, testers and auxiliary items required

Scheme 26

1. Torque wrench V.A.G1332

1. Engine-/transmission jack V.A.G1383A with universal transmission support V.A.G1359/2

Refer to general repair instructions --> General repair instructions .

1. Remove rear section of exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281364-S12921374702008031100000) or --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS .

1. Check whether there is a marking (colored marking) on driveshaft and at flange/driveshaft at rear final drive.
2. If this marking is not present, then mark in color the position of driveshaft flange - arrow A - to rear final drive - arrow B -.
3. Disconnect driveshaft from rear final drive and tie up --> «Driveshaft, separating from rear final drive»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__driveshaft-separating-from-rear-final-drive) .

Scheme 27

1. Remove right and left shielding plates from rear final drive - arrows -.
2. Unbolt left and right drive axles.

Scheme 28

1. Place Engine-/transmission jack V.A.G1383A with universal transmission support V.A.G1359/2 under rear final drive.
2. Secure rear final drive using strap to universal transmission support.

Scheme 29

1. Unscrew securing bolts from transmission support - arrows -.

Scheme 30

1. Remove securing bolts - arrow A - and - arrows B - from crossmember.

Bolt - arrow A - remains in crossmember.

Scheme 31

1. Lower final drive slightly.
2. Turn rear final drive slightly to the side and pull drive axles out of flange shafts alternately on each side.
3. Lower rear final drive out of vehicle.

Rear final drive, installing

Installation is performed in the reverse order of removal. Pay attention to the following

1. Turn rear final drive to the side.
2. Lift rear final drive and fit drive axles into flange shafts alternately on each side.

1. Install securing bolt - arrow A - and tighten lightly to start with.
2. Install securing bolts - arrow B -.
3. Tighten securing bolts - arrow A - and - arrows B

1. Tighten securing bolts - arrows - for final drive support.
2. Attach driveshaft to rear final drive.
3. Checking gear oil in rear final drive --> «Gear oil in rear final drive, checking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
4. Install drive axles --> «42 - REAR SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Install right and left shielding plates on rear final drive - arrows -.

Sealing rings for flange shafts, replacing

1. The oil seals can be only be replaced with the final drive removed.

Scheme 32

Special tools, testers and auxiliary items required

1. Driver 2062
2. Drip tray V.A.G1306
3. Torque wrench V.A.G1331
4. Torque wrench V.A.G1332

1. Sealing grease G052128A1

Special tools, testers and auxiliary items required

1. Engine-/transmission jack V.A.G1383A with universal transmission support V.A.G1359/2

Removing

All illustrations show the left side of the rear final drive. Removing and installing drive flange and oil seal on right side is identical.

1. Observe general repair notes --> «General repair instructions»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
2. Remove rear final drive --> «Rear final drive, removing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__rear-final-drive-removing) .
3. Place drip tray V.A.G1306 underneath.

Scheme 33

1. Unscrew securing bolt for drive flange, to do so screw two bolts in flange and counterhold drive flange using a lever.
2. Pull out flange shaft.

Scheme 34

1. Pry out dust ring using a small screwdriver.

The dust ring will be damaged on removal and must be replaced.

Scheme 35

1. Pry out sealing ring with suitable lever.

Installing

Installation is performed in the reverse order of removal. Pay attention to the following

1. Coat outer edge of gasket with gear oil.
2. Fill area between sealing lip and dust lip halfway with sealing grease G052128A1 .

Scheme 36

1. Drive new seal in as far as the stop; be sure not to distort seal.

Scheme 37

1. Drive in new dust ring - arrow - up to stop.
2. Insert flange shaft.

1. Screw in and tighten securing bolt for flange shaft --> «Torque specifications»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
2. Install rear final drive.
3. Checking gear oil in rear final drive --> «Gear oil in rear final drive, checking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

Scheme 38

Special tools, testers and auxiliary items required

1. Puller VW391
2. Slide hammer VW771
3. Pulling hook VW771/3
4. Driver 3026

1. Counterhold 3028
2. Seal driver - front wheel bearing 3143
3. Sealing grease G052128A1
4. Thread locking compound D000600

1. 2 hex bolts M8x30
2. Hex bolt M10x10010.9

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G1332

1. Engine-/transmission jack V.A.G1383A with universal transmission support V.A.G1359/2

Removing

1. Rear final drive installed

Refer to general repair instructions --> General repair instructions .

1. Remove rear section of exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281364-S12921374702008031100000) or --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS .
2. Disconnect driveshaft from rear final drive and tie up --> «Driveshaft, separating from rear final drive»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__driveshaft-separating-from-rear-final-drive) .

1. Place Engine-/transmission jack V.A.G1383A with universal transmission support V.A.G1359/2 under rear final drive.

1. Unscrew securing bolts from transmission support - arrows -.
2. Lower rear final drive carefully until the driveshaft flange is accessible.

Scheme 39

1. Distance of flange to drive pinion = dimension "a"
2. Distance of flange to securing nut for drive pinion = dimension "b"

1. Take note of the determined dimensions.

Scheme 40

1. Mark position of drive pinion nut with paint - arrow -.

Scheme 41

1. Bolt on Counterhold 3028.
2. Unscrew securing nut for pinion shaft completely. Count the number of turns required and make a note of this number.

Reuse previously installed hex nut for securing flange to drive pinion. Otherwise the original installation position cannot be determined again.

Scheme 42

1. Screw 2 hex bolts M8x30 - A - in flange.
2. Place drip tray V.A.G1306 underneath.
3. Pull off flange using puller VW391.

Scheme 43

1. Pull out sealing ring.

Installing

Installation is performed in the reverse order of removal. Pay attention to the following

Scheme 44

1. Always replace O-ring behind flange.
2. Lightly lubricate outer circumference and sealing lips of oil seal with gear oil.

Scheme 45

1. Coat outer circumference and sealing lips of sealing ring with gear oil.
2. Fill area between sealing lip and dust lip halfway with sealing grease G052128A1 .
3. Drive new seal in as far as the stop; be sure not to distort seal.

Scheme 46

1. Drive on driveshaft flange until securing nut can be fitted onto pinion shaft.
2. The threads on the pinion shaft and securing nut must be cleaned so they are free of grease residue, and then coated thinly with thread locking compound D000600 .

1. Install the originally fitted hexagon nut and tighten to the previously marked position - arrow - by turning the same number of turns as noted on removal.

Scheme 47

Performing measurement check - checking dimension "a" and dimension "b".

1. O-ring - 1 - must be installed for measurement procedure.
2. Hex nut must stand exactly at marked position.

Deviation of measurement --> Determining dimension "a" and dimension "b" may be ± 0.3 mm.

Scheme 48

1. Secure the hex nut.
2. Then install driveshaft to rear final drive.
3. Checking gear oil in rear final drive --> «Gear oil in rear final drive, checking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

Scheme 49

1 - Rear axle housing

2 - Spacer sleeve

1. Always replace

3 - Driveshaft flange

1. Removing and installing --> «Pinion shaft, removing, installing, dismantling and assembling - overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

4 - Pinion

1. Is mated with ring gear, always replace together as a set
2. Removing and installing --> «Pinion shaft, removing, installing, dismantling and assembling - overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

5 - Cover for final drive

6 - Differential

1. Removing and installing --> «Differential, removing and installing - overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Disassembling and assembling --> «Differential, dismantling and assembling»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

7 - Ring gear

1. Mated with drive pinion (final drive set)
2. Removing and installing --> «Differential, dismantling and assembling»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

Differential, removing and installing - overview

1. Rear final drive removed

Refer to general repair instructions --> General repair instructions .

Clamp rear final drive in assembly fixture Clamp rear final drive in assembly fixture

* Adjustment work is necessary when replacing these parts --> Adjustment overview .

Scheme 50

1 - Breather sleeve

1. With rubber valve
2. Installed location «Installed location of breather sleeve»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

2 - Rear axle housing * See note

1. Removing and installing drive pinion --> «Pinion shaft, removing, installing, dismantling and assembling - overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

3 - Large outer race/tapered roller bearing * See note

1. Removing and installing --> «Differential, dismantling and assembling»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

4 - Shim S 1

1. Note thickness
2. List of adjustments --> «Adjustment overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__adjustment-overview)

5 - Cover for rear final drive * See note

1. With O-ring
2. Always replace O-ring
3. Coat O-ring with gear oil and insert

6 - Torx screw, 25 Nm

7 - Seal

1. Replace --> «Sealing rings for flange shafts, replacing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

8 - Hex socket head bolt, 25Nm

9 - Flange shaft

1. Removing and installing «Flange shaft, removing and installing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

10 - Sealing plug, 35 Nm

1. Gear oil in rear final drive, checking --> «Gear oil in rear final drive, checking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Filling quantity and specification --> «Code letters, assembly allocation, ratios»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__code-letters-assembly-allocation-ratios)

11 - Differential with crown wheel * See note.

1. Disassembling and assembling --> «Differential, dismantling and assembling»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

12 - Oil drain plug, 35 Nm

13 - Bushing

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

14 - Magnet

1. Clean after every removal

15 - Small outer race/tapered roller bearing * See note

1. Removing and installing --> «Differential, dismantling and assembling»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

16 - Shim S 2

1. Note thickness
2. List of adjustments --> «Adjustment overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__adjustment-overview)

17 - Seal

1. Replace --> «Sealing rings for flange shafts, replacing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

18 - Flange shaft

1. Removing and installing «Flange shaft, removing and installing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

19 - Hex socket head bolt, 25Nm

20 - Cover

1. Installing «Press cover in onto stop»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

Scheme 51

Scheme 52

1. Unscrew securing bolt for drive flange, to do so screw two bolts in flange and counterhold drive flange using a lever.

Scheme 53

Scheme 54

The breather sleeve must protrude 13 mm - measurement a - out of housing after pressing in.

Slot in rubber valve should be in line with direction of travel.

Scheme 55

Special tools, testers and auxiliary items required

1. Holding fixture VW313
2. Holding fixture VW540
3. Drip tray V.A.G1306
4. Torque wrench V.A.G1331

1. Engine-/transmission jack V.A.G1383A with universal transmission support V.A.G1359/2
2. Sealing grease G052128A1
3. Rear final drive removed --> «Rear final drive, removing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__rear-final-drive-removing) .

Clamp rear final drive in assembly fixture Clamp rear final drive in assembly fixture

1. Place drip tray V.A.G1306 underneath.
2. Drain gear oil.

1. Unscrew securing bolt for drive flange, to do so screw two bolts in flange and counterhold drive flange using a lever.
2. Mark left and right drive flanges and pull out.
3. Unscrew bolts for rear final drive cover and remove cover.
4. Pull out differential and remove.

Installation is performed in the reverse order of removal. Pay attention to the following

1. Replace O-ring for final drive cover and oil before installation.
2. Place cover for rear final drive onto final drive housing and tighten bolts in diagonal sequence.
3. Fill area between sealing lip and dust lip of seal halfway with sealing grease G052128A1 .

1. Install drive flanges and tighten.
2. Tighten oil drain plug on rear final drive.
3. Top-up and check gear oil in rear final drive --> «Gear oil in rear final drive, checking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

Scheme 56

Special tools, testers and auxiliary items required

1. Drift VW295
2. Pressure plate VW401
3. Pressure plate VW402
4. Punch VW407

1. Punch VW408A
2. Punch VW412

Scheme 57

Special tools, testers and auxiliary items required

1. Thrust plate VW442
2. Seal driver - front wheel bearing 40-21
3. Thrust piece 40-105
4. Thrust plate 2050

1. Drift 3138
2. Torque wrench V.A.G1332

Scheme 58

Special tools, testers and auxiliary items required

1. Taper roller bearing puller V.A.G1582
2. Attachment V.A.G1582/6
3. Puller Kukko44/2

Heat inner race/tapered roller bearing to 100° C before installing.

Always replace both taper roller bearings together as a set.

Differential must be adjusted when replacing tapered roller bearings, differential housing, rear final drive cover, gear set and transmission housing --> Ring gear, adjusting .

Clamp rear final drive in assembly fixture Clamp rear final drive in assembly fixture

* Adjustment work is necessary when replacing these parts --> Adjustment overview .

Scheme 59

1 - Cover for rear final drive * See note

2 - O-ring

1. Always replace
2. Lubricate with oil when installing

3 - Rear axle housing * See note

4 - Shim S 1

1. Note thickness
2. List of adjustments --> «Adjustment overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__adjustment-overview)

5 - Small outer race/tapered roller bearing * See note

1. Driving out «Driving small tapered roller bearing/outer race out of housing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Pressing in «Pressing small tapered roller bearing/outer race into housing to stop»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

6 - Small inner race/tapered roller bearing * See note

1. Pulling off «Pulling off small inner race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Pressing on «Pressing on small tapered roller bearing inner race»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

7 - Hex bolt, 60 Nm and turn an additional 45°

1. Always replace
2. Lightly fasten bolts, then tighten in a diagonal sequence to torque specification
3. Allocation

8 - Differential housing * See note

9 - Ring gear * See note

1. Mated with drive pinion (final drive set)
2. Drive off using drift «Drive ring gear from housing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
3. Install on differential housing «Install ring gear»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
4. Allocation

10 - Roll pin

1. For securing the axle for differential bevel gears
2. Drive in flush

11 - Large inner race/tapered roller bearing * See note

1. Pulling off «Pulling off large inner race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Pressing on «Pressing on large inner race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

12 - Large outer race/tapered roller bearing * See note

1. Driving out «Driving off outer race/tapered roller bearing from cover»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Pressing in «Pressing outer race/tapered roller bearing into cover»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

13 - Shim S 2

1. Note thickness
2. List of adjustments --> «Adjustment overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__adjustment-overview)

14 - Threaded piece

15 - Large differential bevel gear

1. Installing «Installing small differential bevel gears»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Adjusting «Differential bevel gears, adjusting»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

16 - Small differential bevel gear

1. Installing «Installing small differential bevel gears»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

17 - Axle for differential bevel gears

1. Drive out with drift

18 - Shim

1. Determining thickness «Differential bevel gears, adjusting»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

19 - Thrust washer

1. Check for cracks

Scheme 60

1. After removing, check shims for damage.

Scheme 61

Scheme 62

A - standard two-arm puller, e.g. puller Kukko44/2

Scheme 63

1. Heat inner race to approx. 100° C before pressing on

Scheme 64

1. Before installing puller, set thrust piece 40-105 onto differential housing.

Scheme 65

1. Heat inner race to approx. 100° C before pressing on

Scheme 66

1. After removing, check shims for damage.

Scheme 67

Scheme 68

Scheme 69

1. Heat ring gear to approx. 100° C and install.
2. When installing ring gear, guide with centering pins - A - (self-made).

Scheme 70

1. If the large differential bevel gears were replaced, adjustment shims must be redetermined «Differential bevel gears, adjusting»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
2. Insert large differential bevel gears with determined adjustment shims.
3. Install small differential bevel gears at 180° from their final position and rotate into place - arrow -.
4. Install and align thrust washers.

1. Insert threaded pieces, be sure to fit properly.
2. Drive the axle for differential bevel gears into final position and secure.

Scheme 71

1. Insert large differential bevel gears with 0.5 mm thick adjustment shims.
2. Install small differential bevel gears offset by 180° together with thrust washers.

Make sure that thrust washers are now no longer swapped.

1. Drive in axle for differential bevel gears.
2. Press small differential bevel gears outward.
3. Push the large differential bevel gears - in direction of arrow - and check backlash.
4. Determine the largest possible shim that can still be installed for the large differential bevel gears on each side.

1. Select shims with same thickness.

Table of adjustment shims

Allocate adjustment shims .

Scheme 72

If no backlash can be measured, differential bevel gears are just able to still be turned, the adjustment is also OK.

Pinion shaft, removing, installing, dismantling and assembling - overview

Always replace both taper roller bearings together as a set.

Install new tapered roller bearing as supplied and do not use additional oil.

Clamp rear final drive in assembly fixture Clamp rear final drive in assembly fixture

* Adjustment work is necessary when replacing these parts --> Adjustment overview .

Scheme 73

1 - Nut

1. Unfastening «Removing nut for pinion»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Fastening «Tightening nut for pinion and adjusting friction torque»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__tightening-nut-for-pinion-and-adjusting)
3. Measure friction torque while doing so «Measure friction torque.»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
4. Securing «Secure nut for pinion»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__secure-nut-for-pinion)

2 - Flange for driveshaft

1. Pulling off «Pulling off flange»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__pulling-off-flange)
2. Installing «Installing flange»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__installing-flange)

3 - Seal

1. Pulling out «Pulling out seal for driveshaft flange»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Driving in «Driving in seal for driveshaft flange»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__driving-in-seal-for-driveshaft-flange)

4 - O-ring

1. Always replace
2. Insert with gear oil «Inserting O-ring»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__inserting-o-ring)

5 - Small inner race/tapered roller bearing * See note

1. Pressing off drive pinion «Pressing off drive pinion from inner race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Installing «Inserting small inner race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

6 - Small outer race/tapered roller bearing * See note

1. Pulling out «Pulling off small outer race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Pressing in «Pressing in small outer race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

7 - Spacer sleeve * See note

1. Always replace

8 - Rear axle housing * See note

9 - Shim S 3

1. Note thickness
2. List of adjustments --> «Adjustment overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__adjustment-overview)

10 - Large outer race/tapered roller bearing * See note

1. Driving out «Driving out large outer race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Pulling in «Pulling in large outer race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

11 - Large inner race/tapered roller bearing * See note

1. Pressing off «Pressing off large tapered roller bearing inner race»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Pressing on «Pressing on large inner race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

12 - Drive pinion * See note

1. Is matched to ring gear
2. When replacing, replace completely

Scheme 74

Special tools, testers and auxiliary items required

1. Puller VW391
2. Pressure plate VW401
3. Pressure plate VW402
4. Punch VW407

1. Punch VW408A
2. Punch VW412

Scheme 75

Special tools, testers and auxiliary items required

1. Support channels VW457
2. Pressing off device VW460
3. Installation ring VW470/1
4. Tube VW519

1. Holding fixture VW540
2. Thrust piece 30-205

Scheme 76

Special tools, testers and auxiliary items required

1. Seal installer 2003/3
2. Thrust piece 3005
3. Counterhold 3028
4. Thrust pad 3062

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

Scheme 77

Special tools, testers and auxiliary items required

1. Slide hammer VW771
2. Driver 3026
3. Alignment fixture 3253
4. Engine-/transmission jack V.A.G1383A with universal transmission support V.A.G1359/2

Scheme 78

Special tools, testers and auxiliary items required

1. Drift VW295
2. Friction meter VAS 6222
3. Separating device Kukko17/2
4. Internal puller Kukko21/7

1. Support Kukko22/2
2. Sealing grease G052128A1
3. Long socket wrench insert SW 36
4. 2 hex bolts M8x30

Scheme 79

A - Screw in 2 hex boltsM8x30 .

B - Long socket wrench insert SW36

1. When loosening nut, rear final drive must be supported using engine-/transmission jack V.A.G1383A and universal transmission support V.A.G1359/2.

Pulling off flange

A - Screw 2 hex boltsM8x30 in flange.

Scheme 80

Scheme 81

A - Support Kukko22/2

B - Internal puller 46 to 56 mm , e.g. Kukko21/7

Scheme 82

1. After removing, check shims for damage.

Scheme 83

A - Separating device 22 to 115 mm , e.g. Kukko17/2

Scheme 84

1. Heat inner race to approx. 100° C before pressing on.

Scheme 85

1. Lightly oil bearing seat in rear axle housing.
2. Insert previously determined adjustment shim S 3 for drive pinion.

The writing "oben ("top")" on the thrust pad 3253/4 faces nut for pulling in tool.

Scheme 86

1. Lightly oil bearing seat in rear axle housing.
2. Use Drift VW295 and thrust plate 30-205 for pressing in outer race.

Scheme 87

1. Insert pinion with new spacer sleeve.

1. Heat inner race to approx. 100° C.
2. Press drive pinion up and press inner race to stop using sleeve 40-21.

Inserting O-ring

1. Insert O-ring with gear oil.

Driving in seal for driveshaft flange

1. Coat outer edge of gasket with gear oil.
2. Fill area between sealing lip and dust lip halfway with sealing grease G052128A1 .
3. Drive in new seal to stop in rear axle housing, without canting seal.

Installing flange

1. Drive flange for driveshaft onto pinion far enough until the nut can be installed.

Tightening nut for pinion and adjusting friction torque

A - Screw in 2 hex boltsM8x30 .

B - Long socket wrench insert SW36

1. When tightening nut, rear final drive must be supported using engine-/transmission jack V.A.G1383A and universal transmission support V.A.G1359/2.

Increase tightening torque gradually, frequently measuring friction torque. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! A spacer sleeve which has been compressed too much cannot be reused.

Scheme 88

To measure friction torque, use friction meter VAS 6222 and long socket insert SW36.

Set following frictional torques

* run for at least 50 km (30 miles)

Secure nut for pinion

1. Secure nut for pinion shaft.
2. Measure radial runout at flange for driveshaft --> «Radial runout at driveshaft flange on rear final drive, measuring and marking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

General notes

Careful adjustment of pinion and ring gear is important for service life and smooth running of final drive. Therefore, drive pinions and ring gears are already paired with each other during manufacture and checked for good mesh pattern and low noise. The position for quietest running is obtained by moving the pinion shaft axially and, at the same time, maintaining the backlash within the specified tolerances.

The deviation "r" from the master gauge "Ro" is marked on the outer circumference of the ring gear.

Only replace gear set (ring gear and pinion shaft) together!

Scheme 89

1 - Identification "O937" means the Oerlikon gear set with a ratio of 37 : 9

A Klingelnberg-gear set "K937" or Gleasen-gear set "G937" can also be installed.

2 - Pairing number - 312 - for gearing set

3 - Dimension "r" is based on the master gauge used on the test bench during production. Dimension "r" is always given in 1/100 mm. Example: "25" means r = 0.25 mm

Ro - Length of test machine master gauge used "Ro"

Ro - Ring gear = 57.50 mm

R - Actual dimension between ring gear axis and face of drive pinion in position of quietest running for this gear set.

Vo - Hypoid offset

Scheme 90

S1 - Adjustment shim for crown wheel in cover for final drive

S2 - Shim for crown wheel in rear axle housing

S3 - Shim for pinion shaft in rear axle housing

Adjustment overview

1. When working on rear final drive, drive pinion or gear set only need to be adjusted if components were replaced which directly influence the final drive. Refer to the following table to avoid unnecessary adjustments

Recommended sequence for adjusting gear set

If drive pinion and gear ring have to be adjusted, the following sequence is recommended for maximum efficiency

1. Determine total shim thickness " S total " (S 1 plus S 2 ) to give specified preload on differential tapered roller bearings.
2. Determine shim thickness " S 3 " required for specified position of pinion shaft.
3. Distribute total shim thickness " S total " (S 1 plus S 2 ) so that the specified backlash between ring gear and drive pinion is achieved.

The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test machine in production. Make sure that all installation and measurement procedures are performed with the utmost care and cleanliness to ensure a successful result.

Pinion, adjusting

Drive pinion only has to be adjusted again according to the following instructions if gear set, tapered roller bearings for drive pinion or rear axle housing were replaced --> Adjustment overview .

Scheme 91

Special tools, testers and auxiliary items required

1. Universal measuring device VW385
2. Holding fixture VW540
3. Torque gauge VAS 6222
4. Dial gauge

1. Long socket wrench insert SW36

Determining thickness of adjustment shim S 3

1. Before adjusting pinion shaft, first determine total shim thickness " S total " (S 1 plus S 2 ) required for specified preload of differential tapered roller bearings --> «Ring gear, adjusting»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__ring-gear-adjusting) .

(adjust preload of tapered roller bearing for drive pinion).

1. Clamp rear final drive in assembly fixture «Clamp rear final drive in assembly fixture»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)
2. Pull both tapered roller bearing outer races without adjustment shims into housing «Pulling in large outer race/tapered roller bearing»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

1. Install new tapered roller bearing as supplied and do not use additional oil.
2. Only install spacer sleeve if friction torque has been adjusted (Shim " S 3 " already determined).

1. Insert drive pinion with inner race/large tapered roller bearing without spacer sleeve into housing.

1. Heat up small tapered roller bearing inner race to approx. 100° C and place on drive pinion.

1. Install flange for driveshaft and tighten hex nut for flange «Tightening nut for pinion and adjusting friction torque»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__tightening-nut-for-pinion-and-adjusting)

Increase tightening torque gradually, frequently measuring friction torque.

To measure friction torque, use friction meter VAS 6222 and long socket insert SW36.

* run for at least 50 km (30 miles)

Scheme 92

1. Set adjusting ring of measuring bar VW385/1 to dimension "a" = 60 mm.
2. Set adjustable ring to dimension "b" = 55 mm.

Scheme 93

1. Assemble universal measuring bar VW385/1 according to (Scheme 93).

1. Dial indicator extension VW385/15 = 9 mm long
2. Set adjustable master gauge VW385/30 to R o = 57.50 mm.
3. Set gauge (3 mm measuring range) to zero with 2 mm preload.

1. Turn drive pinion 8 rotations in each direction to seat the tapered roller bearing.

Scheme 94

1. Place end gauge on drive pinion face.

Scheme 95

1. Remove master gauge and insert measuring mandrel into housing.
2. Attach rear final drive cover and tighten with 4 bolts.
3. Using adjustable ring, pull 2nd centering disc out far enough, so that the mandrel can only just be turned by hand.

Scheme 96

Measure dimension "e".

1. Turn measuring mandrel until dial indicator extension touches end gauge and measure the maximum runout (return point). Measured value is dimension "e" (red numbered area).

1. Example: Dimension "e" = 1.60 mm

" S 3 " = e - r

Example

1. Varying tolerances make it possible to measure the required shim thickness exactly.

Table of adjustment shims

Allocate adjustment shims .

1. Remove universal mandrel.
2. Remove drive pinion and large tapered roller bearing outer race and install together with determined adjustment shim " S 3 " and spacer sleeve --> «Pinion shaft, removing, installing, dismantling and assembling - overview»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
3. Insert small tapered roller bearing inner race and tighten drive pinion nut until specified friction torque is obtained «Tightening nut for pinion and adjusting friction torque»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r__tightening-nut-for-pinion-and-adjusting)

Increase tightening torque gradually, frequently measuring friction torque. If the specified friction torque is surpassed, replace spacer sleeve and repeat adjustment! A spacer sleeve which has been compressed too much cannot be reused.

To measure friction torque, use friction meter VAS 6222 and long socket insert SW36.

* run for at least 50 km (30 miles)

Performing measurement check - checking dimension "r"

1. Turn drive pinion 8 rotations in each direction to seat the tapered roller bearing.

Insert universal mandrel VW385/1 and measure dimension "r".

If adjustment shims were determined correctly, dial indicator must indicate deviation "r" with a tolerance of + 0.05 mm (reading counterclockwise in red number display).

1. Secure the hex nut.
2. After the nut for drive pinion has been secured, the radial runout at driveshaft flange must be measured and marked --> «Radial runout at driveshaft flange on rear final drive, measuring and marking»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

Ring gear, adjusting

(Adjusting differential)

A new ring gear adjustment is necessary if

Rear axle housing, final drive cover, tapered roller bearing for differential, differential housing or gear set are replaced.

Adjustment overview: --> Adjustment overview .

Scheme 97

Special tools, testers and auxiliary items required

1. Magnetic plate VW385/17
2. Dial gauge holder VW387
3. Measuring lever VW388
4. Ring gear adjustment device VW521

1. Torque wrench V.A.G1331
2. Dial gauge
3. Hex bolt M 8 x 45

Total shim thickness " S total " (S 1 plus S 2 ), determining

(adjust preload of tapered roller bearing for differential)

1. Drive pinion is removed!
2. If only the tapered roller bearing for differential has been replaced, ring gear can be removed from differential housing. Drive pinion then does not need to be removed.

1. Pry out seal for flange shaft with lever.
2. Remove outer race/tapered roller bearings for differential and remove adjustment shims --> «Differential, dismantling and assembling»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
3. Press in outer race/tapered roller bearing with a 1.00 mm thick adjustment shim until stop into housing (S 2 -side) --> «Differential, dismantling and assembling»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
4. Insert differential into housing.

Ring gear is on the cover side.

1. Set cover in place and tighten bolts to 25 Nm.

Scheme 98

1. Assemble tools on differential housing on the transmission housing side.
2. Turn final drive with cover side upward
3. Turn differential 8 rotations in each direction to seat the tapered roller bearing.

Scheme 99

1. Install measuring tools.
2. Place magnetic plate VW385/17 on differential.

A - dial gauge extension 30 mm

1. Screw in hex bolt M 8 x 45 - B -.
2. Place dial gauge extension on center of magnetic plate VW385/17.
3. Set gauge (3 mm measuring range) to zero with 2 mm preload.

Scheme 100

1. Move differential up and down - direction of arrow - without turning.
2. Read play on dial gauge.

Example: 0.50 mm

1. If it is desired to repeat the measurement, turn differential 8 rotations in each direction to seat the tapered roller bearing.

" S total " (S 1 plus S 2 ), determining

" S total " = measurement result + preload

The specified bearing preload is obtained by adding a constant preload figure of (0.30 mm) to the reading obtained (0.50 mm) and the thickness of the shim installed (1.00 mm).

Example

1. Install the determined total shim thickness (1.80 mm in the example) behind outer race/tapered roller bearing in housing (S 2 -side).

Allocate adjustment shims .

Determining initial shim thickness " S 1 "

(ring gear side)

Initial shim " S 1 " is replaced with final shim S 1 after backlash has been determined.

Select correct shims for S 1 and S 2 .

1. Varying tolerances make it possible to measure the required shim thickness exactly.

Install determined adjustment shims, S 1 on ring gear side, S 2 opposite ring gear, use 2 adjustment shims if necessary.

Torsional backlash, adjusting

1. Drive pinion with S 3 installed.
2. Differential with shims S total (S 1 + S 2 ) installed in final drive housing

1. Install cover for final drive and tighten bolts to 25 Nm.
2. Turn differential a few times in each direction to seat the tapered roller bearing.

Scheme 101

1. Install measuring tools.
2. Use dial gauge extension VW382/10 (6 mm flat).

Set measuring lever VW388 to dimension "a" = 60 mm.

1. Twist ring gear until stop. Set dial gauge to zero with 1 mm preload, turn back ring gear and read off backlash. Note value.
2. After an additional turn of ring gear approx. 90° , repeat measuring procedure three more times. Add the four measured values and calculate mean backlash.

Calculating mean backlash

Example

Mean backlash = 1.20 mm : 4 = 0.30 mm.

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

Determining shim thickness S 2

(opposite ring gear)

Lift = 0.15 mm

1. Varying tolerances make it possible to measure the required shim thickness exactly.

Allocate adjustment shims .

Determining shim thickness S 1

(ring gear side)

Allocate adjustment shims .

1. Varying tolerances make it possible to measure the required shim thickness exactly.
2. Initial shim " S 1 " is replaced with final shim S 1 after backlash has been determined.

Install determined adjustment shims, S 1 on ring gear side and S 2 opposite ring gear, use 2 adjustment shims if necessary.

Perform check measurement.

Measure backlash four times at circumference.

1. It must be 0.12 to 0.22 mm.

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

See also:
• 43 - SELF LEVELING SUSPENSION
• Code letters, assembly allocation, ratios
• Components
• Driveshaft, removing
• Driveshaft, installing
• Driveshaft, separating from rear final drive
• Rear final drive, removing
• Adjustment overview
• Ring gear, adjusting
• Tightening nut for pinion and adjusting friction torque
• Secure nut for pinion
• Pulling off flange
• Installing flange
• Driving in seal for driveshaft flange
• Inserting O-ring
• Pinion, adjusting