Audi Workshop Service and Repair Manuals

Renewing sealing flange (gearbox end) Special tools and workshop equipment required

t  Open end spanner insert, AF 24 -V.A.G 1332/11-

t  Assembly tool -T10134-

t  Depth gauge -VAS 6082- t  Bolt M6x35 (3x) t  Bolt M7x35 (2x)

Pressing out sealing flange with sender wheel l  Gearbox removed. –  Remove flywheel → Chapter.   Note For illustration purposes, the following procedure is shown with the engine removed. –  Detach intermediate plate from sealing flange and dowel pins -arrows-.

–  Rotate crankshaft by turning bolt for toothed belt sprocket until crankshaft is positioned at „TDC“, as shown in illustration. –  Remove sump → Chapter.

–  Remove engine speed sender -G28--item 1- → Rep. gr.28.

–  Remove bolts -1 ... 6- for sealing flange.   Note Disregard -items 7, 8-.   Note

The sealing flange is pressed off the crankshaft together with the sender wheel. –  To press off, screw 3 bolts M6x35 -arrows- alternately into sealing flange not more than 1/2 turn at a time. –  Take off sealing flange with sender wheel. Pressing in sealing flange with sender wheel   Note t  The sealing flange with PTFE oil seal is fitted with a sealing lip support ring. This support ring acts as an assembly sleeve and must not be removed before installation. t  Sealing flange and sender wheel must not be separated or rotated out of position after removal from packaging. t  The sender wheel is held in its installation position by a locating pin on the assembly tool -T10134-. t  The sealing flange and oil seal are one unit and must always be replaced together with the sender wheel. t  The assembly tool -T10134- is held in the correct position relative to the crankshaft by a guide pin which is inserted into a hole in the crankshaft.

Construction of assembly tool -T10134- A -  Tightening flats B -  Hexagon nut C -  Assembly housing D -  Locating pin E -  Hexagon socket-head bolt F -  Guide pin for diesel engines (black handle) G -  Guide pin for petrol engines (red handle)

A - Fitting sealing flange with sender wheel onto assembly tool -T10134-: –  Turn hexagon nut -B- on threaded spindle until it is just in front of flats -A-.

–  Clamp assembly tool -T10134- in a vice on tightening flats -A- of threaded spindle. –  Press assembly housing -C- downwards so that it lies on hexagon nut -B--arrow-. l  Inner part of assembly device and assembly housing must align (be level) with each other.

–  Remove the securing clip -arrow- from new sealing flange.   Note The sender wheel must not be taken out of the sealing flange or rotated out of position.

l  The locating hole -A- on the sender wheel -C- must align with the marking -B- on the sealing flange. –  Place the sealing flange (with the front side downwards) on a clean flat surface.

–  Press the sealing lip support ring -A- downwards in direction of -arrows- until it lies against the flat surface.

l  The upper edge of the sender wheel and the front edge of the sealing flange must align -arrows-.

–  Place front side of sealing flange on assembly tool -T10134-, so that locating pin -B- can be inserted in hole -A- in sender wheel. l  Ensure the sealing flange lies flat on the assembly tool.

–  Press the sealing flange and sealing lip support ring -B- onto the surface of the assembly tool -T10134- while tightening the 3 knurled screws -A- so that the locating pin will not slip out of the hole in the sender wheel. l  Ensure that the sender wheel remains fixed on the assembly tool when installing the sealing flange.

B - Installing assembly tool -T10134- with sealing flange on crankshaft flange: l  Crankshaft flange must be free of oil or grease. l  Engine is at „TDC“ position. –  Screw hexagon nut -B- to end of threaded spindle. –  Press the threaded spindle of assembly tool -T10134- in direction of -arrow- until the hexagon nut -B- lies on the assembly housing -A-.

–  Position flat edge of assembly housing towards sealing surface for sump on cylinder block. –  Secure assembly tool -T10134- to crankshaft flange by screwing hexagon socket head bolts -A- approx. 5 threads into crankshaft flange.

–  Screw two bolts M7×35 mm -item A- into cylinder block to guide sealing flange.

C - Securing assembly tool -T10134- onto crankshaft flange: –  Press the assembly housing -C- by hand in the direction of the -arrow- until the sealing lip support ring -B- lies on the surface of the crankshaft flange -A-.   Caution Do not interchange components. The guide pin for PETROL engines (red handle) -F- MUST NOT be inserted into the threaded hole in the crankshaft. –  Push guide pin for diesel engine (black handle) -D- into hole in crankshaft. This brings the sender wheel into its final installation position. –  Tighten the two hexagon socket head bolts on assembly tool hand-tight. –  Screw hexagon nut -E- onto threaded spindle by hand until it lies against the assembly housing -C-.

D - Pressing sender wheel onto crankshaft flange with assembly tool -T10134-: –  Tighten hexagon nut on assembly tool -T10134- to 35 Nm. l  A small air gap must be present between cylinder block and sealing flange after tightening hexagon nut to 35 Nm.

E - Checking installation position of sender wheel on crankshaft: –  Screw hexagon nut -E- to end of threaded spindle. –  Remove bolts -A- from cylinder block. –  Unscrew knurled screws -B- from sealing flange. –  Unbolt assembly tool -T10134- from crankshaft flange (remove hexagon socket head bolts from crankshaft flange). –  Detach assembly tool -T10134-. –  Detach sealing lip support ring.

–  Apply depth gauge -VAS 6082- to crankshaft flange.

–  Measure distance between crankshaft flange -A- and sender wheel -B-. l  Specification: Distance -a- = 0.5 mm. –  Press sender wheel in further if distance -a- is too small → Anchor. –  If reading matches specification, continue with assembly → Anchor.

F - Pressing sender wheel in further: –  Secure assembly tool -T10134- to crankshaft flange by tightening hexagon socket head bolts -A- hand-tight. –  Press assembly tool onto sealing flange by hand.

–  Screw hexagon nut -E- onto threaded spindle by hand until it lies against the assembly housing -C-.

–  Tighten hexagon nut on assembly tool -T10134- to 40 Nm. –  Check installation position of sender wheel on crankshaft again → Anchor. –  If distance „a“ is still to small, tighten hexagon nut on assembly tool -T10134- to 45 Nm. –  Check installation position of sender wheel on crankshaft again → Anchor.

–  Tighten sealing flange bolts → Fig.. Assembling: Installation is carried out in the reverse order; note the following: –  Install engine speed sender -G28- → Rep. gr.28. –  Install sump → Chapter. –  Install flywheel → Chapter.