Audi Workshop Service and Repair Manuals

• ● Gearbox installed

• ‒ Observe general repair instructions.

Special tools, testers and auxiliary equipment required

• ◆ Drift VW 195
• ◆ Drift VW 295
• ◆ Extractor lever VW 681
• ◆ Drip tray V.A.G 1306
• ◆ Puller T10037

Notes:

• ◆ Removing and installing oil seal on left-hand side is shown below.
• ◆ The procedure is identical for left and right-hand seals.
• ◆ Exhaust system does not have to be removed.
• ◆ Flange shaft may be with or without a polygon bearing. Allocation => Page 00-3.

Removing

• ‒ Remove heat shield for drive shaft.
• ‒ Unbolt drive shaft from flange on gearbox.

=> Running Gear, Front and Four-wheel Drive; Repair Group 40; Removing and installing driveshaft

• ‒ Turn steering to left onto full lock stop.
• ‒ Tie up drive shaft as high as possible. Do not damage paint on drive shaft.

• ‒ Place drip tray V.A.G 1306 underneath the gearbox.

Note:

In order to prevent damaging the needle roller bearing (polygon bearing) or the differential during removal, the flange shaft must be removed evenly, parallel and without applying one-sided force.

Remove flange shaft (left).

• ‒ → Remove the flange shaft, to do this screw the lower support of puller T10037 into the housing (arrow).

Remove the right flange shaft

• ‒ → Remove the flange shaft, to do this screw the lower support of puller T10037 into the housing (arrow).

• ‒ → Always renew flange shaft circlip.
• ‒ Clamp flange shaft in vice using soft jaws. Use new circlip -A- to press out old circlip from groove in flange shaft.
• ‒ Pull out flange shaft oil seal with VW 681.

→ Assembling flange shaft with polygon bearing

•     1 -    Flange shaft
•     2 -    Needle roller bearing (polygon bearing)
•     3 -    Spacer ring
•     4 -    Circlip
•     5 -    Spacer ring - fitted additionally on shafts with 30 mm spline diameter

Notes:

• ◆ If the polygon bearings do not run smoothly with the flange shaft removed, this does notindicate that the bearings are defective. A test for noisy bearings can only be performed with the bearings installed.
• ◆ Inspect for signs of damage to polygon bearings (such as cracking in outer race).
• ◆ The polygon bearings can only be replaced together with the flange shaft.
• ◆ A spacer ring -5- is fitted between the polygon bearing and the differential large bevel gear on flange shafts with 30 mm spline diameter.

Installing

• ‒ Fill space between sealing and dust lips with a thin layer of multi-purpose grease.
• ‒ Lightly oil outer circumference of seal.
• ‒ → Knock in new oil seal for right-hand flange shaft to a depth of 5.5 mm below outer surface of housing; keep seal straight when installing

Note:

If the old flange shaft is reinstalled after the repair, the oil seal must be knocked in to a depth of approx. 6.5 mm so that the new seal does not run on the same contact surface as the old one.

• ‒ → Knock in new oil seal for left-hand flange shaft to a depth of 5.5 mm below surface of cover using VW 195; keep seal straight when installing

Note:

If the old flange shaft is reinstalled after the repair, the oil seal must be knocked in to a depth of approx. 6.5 mm so that the new seal does not run on the same contact surface as the old one.

• ‒ Drive in flange shaft using drift VW 295.
• ‒ Bolt drive shaft to flange shaft.

• ‒ Fit drive shaft heat shields.
• ‒ Check oil level in gearbox => Page 34-70.

Tightening torques