Rear Final Drive: Specifications Audi S8 D3 facelift

Code letters, ratios, capacities

Scheme 1

Illustrated with 6-speed manual transmission 01E, all wheel drive

Designation

1 - Engine

2 - Clutch

3 - Transmission

4 - Input 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

Arrows point in direction of travel

Gear ratios

Arrows point in direction of travel

Tightening torques

Special tools, testers and auxiliary items

Scheme 2

1. Universal dial gauge bracket VW 387
2. Dial gauge
3. M10 x 85 bolt

Note. The radial run-out must always be measured when the driveshaft flange has been removed from the rear final drive. Remove old paint marking and make new marking. If a new driveshaft is being installed and the marking on the flange shaft of the rear final drive is no longer visible, the point of maximum radial run-out must be measured with a dial gauge and marked with paint. The paint marking on the driveshaft is then brought into alignment with this paint marking. Refer to Installing . The radial run-out can also be measured with the rear final drive installed, but the driveshaft must be disconnected at the rear final drive. Observe notes. Refer to Driveshaft, servicing .

Scheme 3

1. Secure universal dial gauge retainer VW 387 with dial gauge to rear final drive.
2. Position dial gauge on ground circumference in driveshaft flange (arrow) and set to zero with a preload of 1 mm.
3. Turn differential via both rear wheels (left and right flange shafts) until flange on rear final drive completes one rotation.
4. Make a paint marking at point of greatest radial run-out on outside of flange (= greatest distance from axis of rotation).

1. Remove old marks on driveshaft flange.
2. Install driveshaft. Refer to «Driveshaft, removing and installing»(ref-289216-S04598571542008062700000) .

Special tools, testers and auxiliary items

Scheme 4

1. Drip tray V.A.G 1306

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

Scheme 5

1. Remove plug -1- to check oil

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

1. Top up gear oil if necessary. Specification. Refer to «Code letters, ratios, capacities»(ref-289216-S01611146742008062700000) .
2. Install plug.

Tightening torque

Scheme 6

1 - Subframe

1. Removing and installing

Refer to 42 - REAR SUSPENSION ; Rear subframe

2 - Hex bolt

3 - Washer

4 - Self-locking nut

1. Always replace
2. Tightening torque

Refer to 42 - REAR SUSPENSION ; Rear subframe

5 - Hex socket head bolt, 55 Nm

6 - Rear crossmember

7 - Axle shaft

1. Removing and installing

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

8 - Guard plate

9 - Combi bolt, 25 Nm

10 - Support bracket

1. Observe installation sequence. see scheme 39

11 - Hex socket head bolt, 40 Nm + 90°

12 - Hex socket head bolt, 40 Nm

13 - Hex socket head bolt, 20 Nm

14 - Washer

15 - Cover for rear final drive

16 - Combi bolt, 40 Nm

17 - Rear final drive

18 - Self-locking nut

1. Always replace
2. Tightening torque

Refer to 42 - REAR SUSPENSION ; Rear subframe

19 - Washer

20 - Hex bolt

Special tools, testers and auxiliary items

Scheme 7

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

Scheme 8

1. V.A.G 1331 Torque wrench or equivalent
2. V.A.G 1332 Torque wrench or equivalent

Removing

Note. Activate the car jack mode before lifting the vehicle on a hoist (i.e. when there is no weight on the wheels)

Refer to 43 - SELF LEVELING SUSPENSION ; Operation of air suspension; Car jack mode

1. Observe general repair instructions. Refer to «General repair instructions»(ref-289216-S02354890232008062700000) .
2. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s))

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ or 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM ; Removing and installing exhaust system

1. Remove bolts (arrows -A- and -B-) and take off cover.

Scheme 9

1. Check whether there is a factory marking (paint) on driveshaft. If not, mark position of driveshaft flange (arrow -A-) in relation to rear final drive (arrow -B-) with paint.
2. Unbolt driveshaft from rear final drive and tie up. Refer to «Driveshaft, removing and installing»(ref-289216-S04598571542008062700000) .

Scheme 10

1. Remove heat shields from final drive (arrows).
2. Unbolt both axle shafts from flanges on rear final drive

Refer to 42 - REAR SUSPENSION

Scheme 11

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

Scheme 12

1. Remove bolts (arrows) from rear crossmember.

Scheme 13

1. Remove 4 bolts (arrows -A- and -B-) from support bracket.
2. Push rear final drive as far as possible to right.

Scheme 14

1. Lift left side of rear final drive (arrow -A-).
2. Push inner CV joint outward (arrow -B-) and pivot axle shaft out from below.
3. Lower final drive slightly.
4. Lift axle shafts clear.

1. Lower rear final drive out of vehicle.
2. Push axle shaft toward front.

Installing

Install in reverse sequence; note the following points

Note. Always replace self-locking nuts. It is important to clean out the remaining locking fluid from the threaded holes in the flange shaft on the rear final drive after removing the driveshaft. If this is not done the new bolts can seize and then shear when they are removed again. The threaded holes can be cleaned with a thread tap. Renew driveshaft bolts (self-locking). After disconnecting the driveshaft from the rear final drive, the balance disc (thick washer) that may be installed between the lock plate and the socket head bolt must not be re-installed. Replace gaskets on flange shaft (pull off backing foil and stick gasket to flange shaft).

1. To prevent imbalance, the flanges must be installed so that the paint markings (arrows -A- and -B-) are in alignment. Installing driveshaft. Refer to «Installing»(ref-289216-S21149901712009020500000) .

1. Guide right axle shaft into flange shaft when lifting rear final drive into position.
2. Lift rear final drive past left axle shaft and into final position.

Note. All parts must move freely.

1. Push left flange shaft upward (arrow -A-) to lift rear final drive on this side.
2. Simultaneously, push CV joint on axle shaft outward as far as it will go (arrow -B-) and guide CV joint into flange shaft from below.
3. Position final drive in installation position again.

1. Secure final drive to rear cross member (arrows).

Secure final drive to support bracket as follows

1. Thread in bolts -A- and -B- hand-tight (support bracket should be in full contact with final drive). Then tighten bolt -A- and bolts -B- (in that order) using a torque wrench.

1. Replace gasket on driveshaft flange on rear final drive and bolt driveshaft to rear final drive. Refer to --> «Driveshaft, removing and installing»(ref-289216-S04598571542008062700000) .
2. Bolt both axle shafts onto flanges on rear final drive

Refer to 42 - REAR SUSPENSION

1. Top off gear oil in rear final drive and check oil level. Refer to «Rear final drive oil level, checking»(ref-289216-S01691871072008062700000) .

1. Install heat shields on final drive (arrows).
2. Install cover below rear final drive
3. Install rear section of exhaust system

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ or 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM ; Removing and installing exhaust system

Special tools, testers and auxiliary items

Scheme 15

1. Engine/transmission support VW 540

Scheme 16

1. Secure complete rear final drive on engine/transmission support VW 540.

Scheme 17

Special tools and equipment

1. 2062 Drift
2. V.A.G 1306 Drip tray
3. V.A.G 1331 Torque wrench
4. V.A.G 1332 Torque wrench

Special tools and workshop equipment required

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

Removing

1. Observe General repair instructions. Refer to «General repair instructions»(ref-289216-S02354890232008062700000) .

Note. All the illustrations show the left-hand side of the final drive. Removal and installation of flange shaft and seal on the right-hand side is identical.

1. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s))

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ or 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM ; Removing and installing exhaust system

1. Remove bolts (arrows -A- and -B-) and remove cover.

1. Remove heat shields from final drive (arrows).
2. Unbolt axle shaft.

Refer to 42 - REAR SUSPENSION

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

1. Remove bolts (arrows) from rear crossmember.

1. Remove four securing bolts (arrows -A- and -B-) from support bracket.
2. Push rear final drive as far as possible to right.

1. Lift left side of rear final drive (arrow -A-).
2. Push inner CV joint outward (arrow -B-) and pivot axle shaft out from below.
3. Place drip tray underneath.

Scheme 18

1. Remove flange shaft securing bolt by threading two bolts into flange and counterholding flange shaft using a lever.
2. Pull out flange shaft.

Scheme 19

1. Pry out dust ring using a screwdriver.

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

Scheme 20

1. Pry out flange shaft oil seal with a suitable lever.

Installing

Install in reverse sequence; note the following points

1. Half fill volume between sealing lip and dust lip with sealing grease G 052 128 A1.
2. Lightly oil outer circumference of seal.

Scheme 21

1. Drive new seal in onto stop. Do not cant seal.

Scheme 22

1. Drive new dust ring (arrow) in onto stop.
2. Insert flange shaft.
3. Secure flange shaft with countersunk bolt.

1. Push left flange shaft upward (arrow -A-) to lift rear final drive on this side.
2. Simultaneously, push CV joint on axle shaft outward as far as it will go (arrow -B-), and guide CV joint into flange shaft from below.
3. Position final drive in installation position again.

1. Secure final drive to rear crossmember (arrows).

Secure final drive to support bracket as follows

1. Screw in bolts -A- and -B- hand-tight (support bracket should be in full contact with final drive). Then tighten bolt -A- and bolts -B- (in that order) using a torque wrench.
2. Top off gear oil in rear final drive and check oil level. Refer to «Rear final drive oil level, checking»(ref-289216-S01691871072008062700000) .
3. Secure axle shafts

Refer to 42 - REAR SUSPENSION

1. Install heat shields on final drive (arrows).
2. Install cover below final drive.
3. Install rear section of exhaust system

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ or 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM ; Removing and installing exhaust system

Tightening torques

Special tools and workshop equipment required

Scheme 23

1. V.A.G 1383A - Engine/transmission jack with universal mounting V.A.G 1359/2
2. 3028 - Counter-hold tool
3. VW 391 - Drive flange installing tool
4. VW 771 - Multi-purpose tool

1. VW 771/37 Extractor hook
2. 3026 - Punch

Special tools and workshop equipment required

Scheme 24

1. Drift sleeve 3143

1. V.A.G 1331 Torque wrench or equivalent
2. V.A.G 1332 Torque wrench or equivalent

Removing

1. Rear final drive installed

1. Refer to «General repair instructions»(ref-289216-S02354890232008062700000) .
2. Remove rear section of exhaust system (rearward of exhaust pipe clamp(s))

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ or 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM ; Removing and installing exhaust system

Scheme 25

1. Remove bolts (arrows) and remove bottom cover.

1. Check whether there is a factory marking (paint) on driveshaft. If not, mark position of CV joint (arrow -A-) in relation to rear final drive (arrow -B-) with paint.
2. Unbolt driveshaft from rear final drive and tie it up. Refer to «Driveshaft, removing and installing»(ref-289216-S04598571542008062700000) .
3. Position engine/transmission jack V.A.G 1383 A with universal mounting 1359/2 under final drive and secure final drive.

1. Remove 4 securing bolts (arrows -A- and -B-) from support bracket.
2. Carefully lower final drive until flange is accessible (not more than 35 mm).
3. Mark position of drive pinion securing nut with paint.

Measuring dimension "a" and dimension "b"

Scheme 26

1. Distance from flange to drive pinion =

Dimension a

1. Distance from flange to drive pinion securing nut =

Dimension b

1. Note measurements.

Note. When removing the securing nut, count and make a note of the number of turns.

Note. Illustrations show the final drive removed for the following work sequence. Use the existing securing nut for securing the flange to the drive pinion, otherwise it will not be possible to obtain the original installation position.

Scheme 27

1. Mount counter-hold tool 3028 and remove drive pinion securing nut.
2. Place drip tray underneath.

Scheme 28

1. Pull off flange with removal tool VW 391.

A - Thread two M 8 x 30 hex bolts into flange.

Scheme 29

1. Pull out seal.

Installing

Install in reverse sequence; note the following points

Scheme 30

1. Replace O-ring between drive pinion bearing and flange.
2. Lightly oil O-ring before installing.
3. Half fill volume between sealing lip and dust lip with sealing grease G 052 128 A1.
4. Lightly oil outer circumference of seal.

Scheme 31

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

Scheme 32

1. Drive driveshaft flange onto drive pinion until retaining nut can be installed.
2. Clean drive pinion nut and threads on drive pinion of oil and grease residues. Thinly coat threads with locking fluid D 000 600.
3. Thread on existing securing nut and tighten as far as original marking.

Note. The number of turns when threading the nut on must be the same as when removing the nut.

Check dimension "a" and dimension "b". Refer to --> (Scheme 27)

Scheme 33

Note. Seal -1- must be installed when measuring. The hex nut must be exactly on the marked position again. Maximum deviation from the original measurement: ± 0.3 mm.

Scheme 34

1. Secure hex nut in position.
2. Position final drive in installation position again.

Secure final drive to support bracket as follows

1. Thread in bolts -A- and -B- hand-tight (support bracket should be in full contact with final drive). Then tighten bolt -A- and bolts -B- (in that order) using a torque wrench.

If the position of the driveshaft in relation to the driveshaft flange was marked before removal, re-install driveshaft in same position. Refer to --> Driveshaft, removing and installing .

If there was a factory marking on the driveshaft, measure the radial run-out at the driveshaft flange on the final drive. Refer to Measuring and marking radial run-out at driveshaft flange on rear final drive . Install the driveshaft so that the paint marking on the driveshaft is aligned with the new marking on the flange.

1. Replace gasket on driveshaft flange and bolt driveshaft onto rear final drive. Refer to --> «Driveshaft, removing and installing»(ref-289216-S04598571542008062700000) .
2. Top off gear oil in rear final drive and check oil level. Refer to «Rear final drive oil level, checking»(ref-289216-S01691871072008062700000) .
3. Install bottom cover on rear final drive.
4. Install rear section of exhaust system.

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ or 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM ; Removing and installing exhaust system

Tightening torques

Scheme 35

1 - Final drive housing

2 - Spacer sleeve

1. Always replace

3 - Flange for driveshaft

1. Removing and installing. Refer to «Drive pinion, removing, installing, disassembling and assembling»(ref-289216-S33730261542008062700000)

4 - Drive pinion

1. Is mated with ring gear, always replace together as a set
2. Removing and installing. Refer to «Drive pinion, removing, installing, disassembling and assembling»(ref-289216-S33730261542008062700000)

5 - Cover for final drive

6 - Differential

1. Removing and installing. Refer to «Differential, removing and installing»(ref-289216-S08930956592008062700000)
2. Disassembling and assembling. Refer to «Differential, disassembling and assembling»(ref-289216-S07177048242008062700000)

7 - Ring gear

1. Is mated to drive pinion (gear set)
2. Removing and installing. Refer to «Differential, disassembling and assembling»(ref-289216-S07177048242008062700000)

Tightening nut for drive pinion and setting friction torque

1. Thread in two M8 x 30 hex bolts -A-.

B- = Socket attachment (long) 36 mm A/F

The final drive must be supported when tightening the nut (e.g. using universal transmission attachment V.A.G 1359/2 in conjunction with engine/transmission jack V.A.G 1383 A).

Note. Increase tightening torque slowly and check friction torque at regular intervals. If the specified friction torque is exceeded the spacer sleeve must be replaced and the adjustment repeated. A spacer sleeve which has been compressed too much cannot be reused.

Scheme 36

With torque gauge, 0 to 600 Ncm, commercially available

B- = Socket attachment, 36 mm A/F

Note. Use 3/4 " to 1/2 " adapter if necessary.

Friction torque to be set

1) run at least 50 km (30 miles)

Measuring frictional torque (check)

1. Drive pinion removed
2. Differential installed with shims "S1*" and "S2*"

Scheme 37

1. Mount torque gauge 0 to 600 Ncm -A- onto differential.
2. Read frictional torque.

Frictional torque specifications

1) run at least 50 km (30 miles)

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