Audi Workshop Service and Repair Manuals

Removing

• ‒ Remove front exhaust pipes.
  => corresponding Workshop Manual for Engine, Mechanical Components; Repair group 26; Removing and installing exhaust system

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

• ‒ → Unscrew propshaft -1- from gearbox and place onto heat shield -2- ; Removing and installing propshaft.
• ‒ Secure propshaft with wire -arrow- at bracket -3- of fuel lines.
• ‒ Drain off gear oil from transfer gear housing => Page39-40

• ‒ → Loosen securing bolts -arrows- for transfer gear housing in diagonal sequence and remove.

• ‒ → Pull off Torsen differential towards rear from output shaft.

Installing

Installation is carried out in the reverse order; note the following:

• ‒ → Check to ensure that the dowel sleeves -arrow A- and -arrow B- are fitted.
• ‒ Install gasket.

Note:

Thinly coat sealing surface -D- with gear oil in order to prevent slipping of seal.

• ‒ Clean the magnet and insert it in chamber -1- on the casting of the intermediate flange.

• ‒ Top up with 200 ml gear oil in Torsen differential casing (see also Topping up gear oil with transfer gear housing removed and dismantled => Page 39-44).
• ‒ → Attach Torsen differential to splines of output shaft and lowest spur gear. Whilst doing so twist slightly.
• ‒ Check whether the attached Torsen differential can be turned manually.

• ‒ → Place the transfer gear housing complete with the fitted spur gears and rear drive flange on the gearbox.
• ‒ Insert bolts for transfer gear housing and tighten to end stage diagonally and in several stages.
• ‒ Bolt the propshaft onto the gearbox flange => Page 39-77, Removing and installing propshaft.
• ‒ Top up transfer gear with gear oil, and check oil level => Page 39-40

Tightening torques