Audi Workshop Service and Repair Manuals

Exploded view – propshaft with detachable centre bearing (up to 05.07) The propshaft with detachable centre bearing was installed as follows: t  Audi TT up to vehicle identification number 8J-8-011 000 t  Audi A3 up to and including model year 2007

Special tools and workshop equipment required

t	Drive flange installing tool -VW 391-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408A-

t	Drift sleeve -VW 244B-

t	Support sleeve -VW 522-

t	Tensioner -40-204A-

t	Hose clip pliers -V.A.G 1275/-

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

t	Circlip pliers -VW 161A-

t	Puller -2 - Kukko 18/0-

t	Splitter -3 - Kukko 17/1-

t  Thrust plate -40 - 105-

t  Two-arm puller -1 Kukko 20/10-

t  Support plate -T10108/1-   Note t  In order to achieve the quietest possible running, only the complete propshaft is balanced during manufacture. The balancing of the complete propshaft or the individual propshaft tubes cannot be carried out with workshop equipment. Therefore, if the front or rear propshaft tube is damaged, always renew the complete propshaft. t  Do not bend propshaft; only store and transport fully extended. t  Before removing, mark the positions of all parts in relation to each other. Reinstall in the same position to avoid excessive imbalance, resulting in bearing damage and rumbling noise. t  Removing and installing propshaft → Chapter

1 -	Manual gearbox with bevel box

2 -

Bolt

q	50 Nm + 90°

q	Always renew

3 -	Flexible coupling with heat shield

q	Installation position: open side of heat shield points towards gearbox

q	Removing and installing → Chapter

4 -

Bolt

q

60 Nm

q	Allocation → Fig.

5 -	Centring sleeve

6 -	Propshaft tube (front)

q	Do not damage centring sleeve -5- and seal in centre of flange when removing and installing

7 -

Bolt

q

40 Nm

8 -	Lock plate

9 -

Clamp

q	Tightening → Fig.

10 -	Boot for constant velocity joint

q	Drive off with a drift before pressing off CV joint

q	Check for damage

11 -	Dished spring

q	Inner diameter serrated

q	Installation position: large diameter lies against CV joint

12 -

Gasket

q	Renew; pull off backing and stick onto joint

13 -	Constant velocity joint

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Press 25 g G-6.3 grease from each side (in total 50 g) into joint. Regrease joint if necessary when renewing boot

14 -

Circlip

q

Renew

q	Remove and install using circlip pliers -VW 161A-

15 -

Bolt

q

45 Nm

16 -

Washer

q	Always renew

17 -

Flange

q	Pulling off → Fig.

q	Pulling on → Fig.

18 -	Centre bearing

q	Pulling off → Fig.

q	Installation position → Fig.

q	Driving on → Fig.

19 -

Bolt

q

25 Nm

q	Also secures heat shield

20 -	Propshaft tube (rear)

q	Do not damage centring sleeve -5- and seal in centre of flange when removing and installing

q	Clamp in a vice to loosen and tighten bolt connections → Fig.

21 -	Centring sleeve

22 -

Bolt

q

60 Nm

q	Allocation → Fig.

23 -	Balancing nut

q

10 Nm

q	Not fitted on all propshafts

q	If the flange bolt → Item was loosened, the balancing nut and the balancing washer → Item must NOT be re-installed.

24 -	Balancing washer

q	Only fitted on balanced final drive units

25 -

Bolt

q	50 Nm + 90°

q	Always renew

26 -	Flexible coupling with vibration damper

q	Installation position → Fig.

27 -	Rear final drive

q	Removing and installing → Chapter

Pressing off constant velocity joint

Pressing on constant velocity joint –  Press on carefully. –  Tighten tensioner -V.A.G 40-204A- firmly; propshaft must not move out of position in tensioner, as this will cause paint damage. –  If necessary, repair paint damage as follows: remove grease residue with nitro thinner -L 001 600-. Apply 2-component acrylic paint -ALN 769 041- with hardener -ALZ 009 001-.

Tightening clip Refer to → Electronic parts catalogue for clip required in the event of a repair.

Clamp rear propshaft tube into a vice using support plate -T10108/1-. –  Secure support plate -T10108/1- to flexible coupling of propshaft tube. –  To do so, fit nuts -B- onto bolts -A- between support plate -T10108/1- and flexible coupling. A -  Bolt M10 x 70 mm with nut B -  M12 nut

Pulling off flange

Pressing on flange

Pulling off centre bearing –  The rubber guide of the centre bearing must be cut and the metal cover removed. A -  Splitter 12...75 mm, e.g. -Kukko 17/1- B -  Puller, e.g. -Kukko 18/0- –  Tighten splitter-A- with straight side of jaws behind centre bearing. –  Then apply two-arm puller-B- to splitter. –  Pull centre bearing off propshaft tube.

Installation position of centre bearing The longer shoulder -A- points to left -arrow- (as seen in direction of travel).

Driving on centre bearing –  Drive on centre bearing until limit stop.

Installation position of flexible coupling with vibration damper The shoulder on the outer circumference -arrows- must point away from the propshaft tube.