Audi Workshop Service and Repair Manuals

Removing and installing transfer box with centre differential

Removing –  Remove front exhaust pipes → Rep. Gr.26.   Caution Do not run the engine or tow the vehicle if the transfer box is removed or if the gear oil has been drained. –  Unbolt heat shield for propshaft -arrows-.

–  Unbolt propshaft -1- from gearbox → Rear final drive 01R; Rep. Gr.39 or → Rear final drive 08V; Rep. Gr.39 and rest propshaft on heat shield -2-. –  Secure propshaft with wire -arrow- on bracket -3- for fuel pipes, or support propshaft with engine and gearbox jack -V.A.G 1383 A-. –  Drain gear oil from transfer box → Chapter.

–  Loosen securing bolts -arrows- for transfer box housing in diagonal sequence and remove bolts.   Caution Detach transfer box housing from gearbox carefully towards the rear. Take care that centre differential does not drop out of gearbox.

–  Pull centre differential -arrow- off output shaft towards the rear.

Installing Installation is carried out in reverse sequence; note the following: –  Check that dowel sleeves -arrow A- and -arrow B- are fitted. –  Install gasket.   Note Apply a thin coating of gear oil to sealing surface -D- to prevent gasket from slipping. –  Clean the magnet and insert it in chamber -1- on the casting of the intermediate flange. –  Put 200 ml of gear oil into output cup (filling up with gear oil after transfer box has been removed and dismantled → Chapter).

–  Fit centre differential -arrow- onto splines of output shaft and lowest spur gear, turning it slightly at the same time. –  Check whether centre differential can be turned by hand after being fitted.

–  Fit transfer box housing (with spur gears and rear output flange installed) onto gearbox flange. –  Insert bolts for transfer box housing and tighten to final torque in diagonal sequence and in several stages. –  Bolt propshaft onto gearbox → Rear final drive 01R; Rep. Gr.39 or → Rear final drive 08V; Rep. Gr.39. –  Fill transfer box with gear oil and check oil level → Chapter. Tightening torques

Component	Nm
Transfer box housing to gearbox housing	23
Heat shield for propshaft to gearbox	23