Audi Workshop Service and Repair Manuals

• ● Gearbox installed

• ‒ Observe general repair instructions.

Special tools, testers and auxiliary equipment required

• ◆ Extractor lever VW 681
• ◆ Mandrel 30-505
• ◆ Press tool 30-506 B
• ◆ Set of ring spanners for lambda probe 3337
• ◆ Drip tray V.A.G 1306

Removing

Vehicles with 4-cylinder engine:

• ‒ Remove rear section of exhaust system from clamp(s):

=> 4-cylinder Engine (5-valve), Mechanical Components; Repair Group 26; Removing and installing exhaust system parts

=> 4-cylinder Engine (5-valve turbo), Mechanics; Repair Group 26; Removing and installing parts of exhaust system

=> 4-cylinder Diesel Direct Injection Engine (TDI), Mechanics; Repair Group 26; Removing and installing exhaust system

Vehicles with 6-cylinder engine:

• ‒ Unscrew lambda probes on right exhaust pipes with special tool 3337 and move clear to the side.

• ‒ Detach heat shield above right drive shafts.
• ‒ → Unbolt front exhaust pipes with catalytic converters from left and right exhaust manifolds (3 nuts on each side) -arrows-:

=> 6-cylinder Engine (2-valve), Mechanics; Repair Group 26; Removing and installing exhaust system

=> 6-cylinder Engine (5-valve), Mechanical Components; Repair Group 26; Removing and installing exhaust system parts

All models:

• ‒ → Remove heat shield for propshaft from cover for Torsen differential -arrows-.

• ‒ → Unscrew propshaft -1- from gearbox and place onto heat shield -2-.
• ‒ Secure propshaft with wire -arrow- at bracket -3- of fuel lines.
• ‒ Place drip tray V.A.G 1306 underneath and drain gearbox oil.

• ‒ Place drip tray V.A.G 1306 below cap.

Note:

→ Oil flows out when sealing cap -B- is removed.

• ‒ Remove circlip -A-.
• ‒ Screw M8 bolt into thread of sealing cap.
• ‒ Pull out sealing cap using bolt.

• ‒ → Open out circlip and pull out flange shaft.

• ‒ → Pull out flange shaft oil seal with VW 681.

Installing

• ‒ Fill space between sealing and dust lips with multipurpose grease.
• ‒ Lightly oil outer circumference of seal.
• ‒ → Knock in new oil seal for flange shaft to a depth of 2 mm below outer surface of housing; keep seal straight when installing
• ‒ Insert flange shaft.

• ‒ → When inserting flange shaft, fit circlip at the same time.
• ‒ Circlip must be properly seated in the base of the groove
• ‒ Fit new O-ring for sealing cap.
• ‒ Fit plug and secure in position.
• ‒ Bolt on propshaft => Page 39-83.

• ‒ Top up oil in gearbox and check oil level => Page 34-69.
• ‒ Stress free alignment of exhaust system

=> 4-cylinder Engine (5-valve), Mechanics; Repair Group 26; Removing and installing exhaust system parts, Stress-free alignment of exhaust system

=> 4-cylinder Engine (5-valve turbo), Mechanics; Repair Group 26; Removing and installing exhaust system parts, Stress-free alignment of exhaust system

=> 4-cylinder Diesel Direct Injection Engine (TDI), Mechanics; Repair Group 26; Removing and installing exhaust system

=> 6-cylinder Engine (2-valve), Mechanics; Repair Group 26; Removing and installing exhaust system

=> 6-cylinder Engine (5-valve), Mechanics; Repair Group 26; Removing and installing exhaust system parts, Stress-free alignment of exhaust system

Tightening torques