Audi Workshop Service and Repair Manuals

Installing bevel box Installation is carried out in reverse sequence; note the following: t  Renew gaskets, seals and self-locking nuts. –  Push bevel box fully onto gearbox, ensuring that splines of bevel box input shaft and differential are centred when brought together. –  Also align the teeth of the flange shaft (right-side) and the differential pinion; if necessary turn the flange shaft. –  If the teeth are correctly positioned and the components are located centrally, the bevel box will slide against the gearbox onto the stop.

–  Secure bevel box to gearbox -arrows-. Tightening torque →    Note Do not use the securing bolts to pull the bevel box onto the gearbox. This could cause the bevel box to tilt and the securing eyes could break off.

–  Install gearbox carrier -A-. Note the correct assembly sequence → Anchor.

Vehicles with diesel engine and particulate filter: –  Install bracket for turbocharger. To do so, tighten bolt -2- and banjo bolt -3- → Rep. Gr.21. –  Install bracket for particulate filter → Rep. Gr.26.

–  Install flange shaft (right-side) → Anchor. Continued for all vehicles:

–  Tighten bolt for flange shaft (right-side) -arrow 1- using socket and extended bit -T10107 A-. –  Install drive shaft (right-side) → Rep. Gr.40. –  Install subframe → Rep. Gr.40. –  Attach steering box to subframe → Rep. Gr.48. –  Press engine/gearbox assembly towards bulkhead, taking care to guide pin on bevel box into propshaft flange.   Note t  When removing and installing the bevel box do not damage the seal in the propshaft flange. Renew propshaft if damaged. t  Ensure propshaft is horizontal when pushing it onto centring pin.

–  Secure pendulum support to gearbox with bolts -2- and -3- (use new bolts → Item). –  Bolt flexible coupling on propshaft onto bevel box flange → Rear final drive 02D, 0AV, 0BR and 0BY; Rep. Gr.39. –  If previously removed, install front left vehicle level sender -G78-. –  Assemble exhaust system and install all exhaust system brackets → Rep. Gr.26. –  Check oil level in bevel box → Chapter. –  Check gear oil level in manual gearbox and top up as required → Chapter. –  Install noise insulation → Rep. Gr.66. –  Fit wheels → Rep. Gr.44.

Heat shield for drive shaft (right-side) –  Tighten bolts -arrows- to 20 Nm.

Assembly sequence: securing gearbox carrier for bevel box to engine and bevel box Vehicles with TFSI engine: –  Screw in bolts -arrows 1- (hand-tight). –  Tighten bolts -arrows 2- → Item. –  Tighten bolts -arrows 1- → Item.

Vehicles with V6 engine: –  Screw in bolts -A- (hand-tight). –  Tighten bolts -B- → Item. –  Tighten bolts -A- → Item.

Vehicles with TDI engine without particulate filter –  Screw in bolts -arrows 1- (hand-tight). –  Tighten bolts -arrows 2- → Item. –  Tighten bolts -arrows 1- → Item.

Vehicles with TDI engine with particulate filter Allocation of bolts:

Item	Bolt	Qty.
1	M10 x 21	3
2	M10 x 45 t  The bolt head was modified to match the head of the other bolts shortly after start of production	2
3	M10 x 62	1

–  Screw in all bolts hand-tight. –  Tighten bolts -arrows 2- and -arrow 3- → Item. –  Tighten bolts -arrows 1- → Item.