Audi Workshop Service and Repair Manuals

Renewing oil seal for flange shaft (Gearbox fitted in vehicle) –  Refer to general repair instructions → Chapter.

Special tools and workshop equipment required

t

t	Drift -VW 295-

t	Release lever -VW 681-

t	Punch -2062-

t	Puller -T10037-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t  Drip tray, e.g. -VAS 6208- t  Sealing grease -G 052 128 A1- Removing flange shaft oil seal   Note t  The procedure for removing the oil seals is identical on both sides. t  The exhaust system does not have to be removed.

–  If fitted, loosen quick-release fasteners -2- and -3- and remove rear noise insulation -B-. –  Turn steering to left onto full lock. When renewing oil seal (right-side):

–  Detach cover plates above drive shaft (right-side) -arrow 1- and -arrow 2-. When renewing oil seal (left-side): –  If fitted, remove cover plate above drive shaft (left-side). Continued for both sides: –  Unbolt drive shaft from flange on gearbox. –  Tie-up drive shaft as high as possible. Do not damage paint on drive shaft. –  Place drip tray e.g. -VAS 6208- under the gearbox.

When renewing oil seal (left-side) –  Remove flange shaft (left-side); to do so, secure puller -T10037- to cover for final drive -arrow-.

When renewing oil seal (right-side) –  Remove flange shaft (right-side); to do so, secure puller -T10037- to gearbox housing -arrow-. Continued for both sides:

–  Always renew circlip for flange shaft. –  Clamp flange shaft in vice, using jaw protectors. Use new circlip -A- to press old circlip out of groove in flange shaft. –  Pull out flange shaft oil seal using oil seal extractor -VW 681-.

Assembling flange shaft with polygon bearing 1 -  Flange shaft 2 -  Needle bearing (polygon bearing) 3 -  Spacer ring 4 -  Circlip 5 -  Spacer ring - fitted additionally on shafts with 30 mm spline diameter   Note t  If the polygon bearings do not run smoothly with the flange shaft removed, this does not necessarily indicate that the bearings are defective. A test for noisy bearings can only be performed with the bearings installed. t  Inspect for signs of damage to polygon bearings (such as cracking in outer race). t  The polygon bearings can only be renewed together with the flange shaft. t  A spacer ring -5- is fitted between the polygon bearing and the differential sun wheel on flange shafts with 30 mm spline diameter. Installing flange shaft oil seal   Note t  Installation depth (for repairs): 6.5 mm when using old flange shaft t  The oil seal can also be driven in with drift -VW 195-. –  Lightly oil outer circumference of oil seal.

–  Knock in new oil seal for flange shaft (right-side) to a depth of 5.5 mm below surface of housing; keep seal straight when installing. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.

–  Knock in new oil seal for flange shaft (left-side) to a depth of 5.5 mm below surface of cover; keep seal straight when installing. –  Knock flange shaft in with drift -VW 295-. –  Bolt drive shaft to flange shaft → Rep. Gr.40. –  Bolt on cover plates for drive shaft if previously fitted. –  Fill up oil in gearbox and check oil level → Chapter. –  Install rear noise insulation (if fitted). Tightening torque

Component		Nm
Drive shaft heat shields		23