Audi Workshop Service and Repair Manuals

Removing and installing centre differential with gearbox installed Special tools and workshop equipment required

t  Engine and gearbox jack -V.A.G 1383 A-

t  Counterhold tool -T10172- with adapters -T10172/5-

t  Gearbox support -T10337-

t  Used oil collection and extraction unit -V.A.G 1782-

t  Torque wrench -V.A.G 1331- Removing

–  Open quick-release fasteners -2 and 3- and remove noise insulation (rear). Vehicles with diesel engine –  In addition, remove front noise insulation (open fasteners -1-).

–  Remove bolts -1- and detach torque reaction support from engine.   Note Items marked -2- and -3- can be disregarded.

Continued for all vehicles –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Unscrew plug -arrow- and drain off gear oil. –  Screw plug -arrow- back in and tighten to 45 Nm.   Note

The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged. –  Disconnect exhaust system at clamp(s) -arrows-.

–  If fitted, remove bolts -arrows- and detach heat shield -A- for propshaft.

Propshaft with bolted connection at gearbox end: –  Remove securing bolts from connection between propshaft and gearbox (counterhold using counterhold tool -T10172- and -T10172/5-). –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie propshaft up to one side. Propshaft with splined connection at gearbox end: –  Remove propshaft → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BD; Rep. gr.39.

Continued for all vehicles –  Support gearbox using engine and gearbox jack -V.A.G 1383 A- with gearbox support -T10337- attached.   WARNING Risk of accident. Engine and gearbox jack -V.A.G 1383 A- must remain in position when work is being carried out and must not be left unattended.

–  Remove bolts -arrows- for tunnel cross member.

–  Lower gearbox by dimension -a- using engine and gearbox jack -V.A.G 1383 A-. l  Dimension -a- = 80 mm (maximum)

–  Unscrew nuts -arrows- and remove tunnel cross member.

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Remove bolts -A-, -B- and -arrows- securing centre differential housing -C- to gearbox cover.   Note The centre hex studs -B- are not fitted on all versions.   Caution Risk of damage to the centre differential. t  Pull the centre differential housing slowly and carefully towards the rear off the gearbox. The centre differential may otherwise fall out of the gearbox. t  A centre differential which has fallen to the ground can no longer be installed. It must be renewed.

–  Carefully pull off centre differential housing -6-, together with spring -3-, shim -4- and dished spring -5-. –  Detach centre differential -2- and bearing plate -1-.

If bearing plate -1- remains behind in centre differential housing, proceed as follows: –  Grip one of side ribs on bearing plate -1- with pliers and pull off in direction of -arrow A-. –  While doing so, carefully tap alternate sides of housing -arrows B- with a rubber-headed hammer.   Caution Take care not to damage sealing surface!

Installing centre differential housing l  Tightening torques → Chapter „Exploded view – centre differential and centre differential housing“ –  Thoroughly clean both housing joint surfaces. Install bearing plate on gearbox as follows: l  Installation position: lug -arrow A- on bearing plate -2- must engage in recess -arrow B- in gearbox cover. l  Oil collector -1-, spacer sleeve -3- and shim -4- are installed.

–  Slide on centre differential -2- towards bearing plate -1- as far as stop. –  Insert dished spring -5-, shim(s) -4- and spring -3- into centre differential housing -6-. l  Installation position of dished spring -5-: inner diameter (convex side) -arrow- faces centre differential housing -6-. –  Apply sealing paste -AMV 188 001 02- evenly and not too thickly. –  Then fit centre differential housing -6- onto gearbox.

–  Press centre differential housing -C- fully onto gearbox cover and hold in place. –  Fit new bolts -A-, -B- and -arrows- and tighten to specified torque → Chapter.   Note The centre hex studs -B- are not fitted on all versions, for allocation refer to → Electronic parts catalogue. In this case, bolts → Item are fitted in place of the centre hex studs.

–  Install tunnel cross member and tighten → Chapter.

Vehicles with diesel engine –  Push torque reaction support -1- upwards in direction indicated by -arrow- until it makes contact with cross member.   Note Bump stop -2- must be in contact with cross member without play, but must not be under tension. –  Then tighten bolts -3- to specified torque → Rep. gr.10.

Continued for all vehicles –  Install propshaft/bolt propshaft onto gearbox → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BD; Rep. gr.39.

–  If fitted, install heat shield for propshaft -A- and tighten bolts -arrows- to 25 Nm. –  Fill up with gear oil and check gear oil level → Chapter. –  Assemble exhaust system and align free of stress → Rep. gr.26. –  Install noise insulation → Rep. gr.66.