Audi Workshop Service and Repair Manuals

Replacing oil seal for pinion shaft

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	Insert tool -T10023-

t	Removal and assembly tool -T40107-

t	Assembly lever

t	Cleaning fluid -D 009 401 04-

Removing l  The pinion shaft oil seal can be replaced with the gearbox in position. –  Drain off ATF → Chapter. –  Remove differential → Chapter. –  Remove flange shaft (right-side) → multitronic 01J, front-wheel drive; Rep. Gr.39, → multitronic 0AN, front-wheel drive; Rep. Gr.39.   Note Flange shaft (right-side) does not have to be removed completely if not readily accessible on the vehicle. In this case, it is sufficient to pull it slightly out of the gearbox housing until there is enough room to remove and install the oil seal.

Caution When performing the following operations, the surface of the pinion shaft must not be allowed to come into contact with hard objects. Freedom from leaks can no longer be achieved in the event of even minute scratches or damage at the sealing surface of the pinion shaft and the entire gearbox must be replaced. –  Position an awl at one of the holes in the side of the pinion shaft oil seal and make a small hole -arrow- for fitting a self-tapping screw in the oil seal.

–  Screw a self-tapping screw with a large head into the hole in the oil seal.

–  Make a notch -arrow- in the centre of a sturdy assembly lever -1- to hold the self-tapping screw. –  Apply the assembly lever to the self-tapping screw.   Caution For protection, insert a suitable piece of wood or plastic -2- between the assembly lever and gearbox housing. Take care not to damage the housing. –  Pull out the oil seal.

Installing –  Assess the pinion shaft for wear → Chapter. –  Use compressed air to clean breather passage -arrow-. When doing so, place a cloth on inside of breather passage.

–  Clean the sealing surface -arrow- of the pinion shaft with cleaning fluid -D 009 401 04- and a soft cloth whilst turning the pinion shaft. l  The selector lever on the gearbox must not be in position “P”. –  Remove stubborn deposits with finger nail; never use tools.   Caution The pinion shaft is never to be cleaned mechanically with tools or polishing paste. Freedom from leaks can no longer be achieved in the event of even minute scratches or damage at the sealing surface of the pinion shaft and the entire gearbox must be replaced. –  Lightly lubricate outer circumference of oil seal with ATF. –  Check assembly aid -T40107/2- for cracks or burrs. Do not use assembly aid if damaged.

–  Attach assembly aid -T40107/2- to thrust sleeve -T40107/1- and slip oil seal -1- onto thrust sleeve. l  Closed side of oil seal faces tool. –  Detach assembly aid -T40107/2-. –  Position the thrust sleeve -T40107/1- with the oil seal -1- on the pinion shaft.

–  Set the selector lever on the gearbox to position “P” (completely to rear). –  Turn nut on spindle -T40107/3- all the way back. –  Use an open-ended wrench to screw in the spindle -T40107/3- as far as it will go.   Note This positions the spindle firmly against the pinion shaft. –  Move thrust sleeve -T40107/1- to correct position. l  Lugs -arrows- on outer edge of thrust sleeve must engage in recesses on gearbox housing.

–  Press oil seal with thrust sleeve into gearbox housing. To do so, tighten nut with torque wrench -V.A.G 1331- and insert tool -T10023- to 17 Nm. l  The oil seal must now be allowed to settle for 2 minutes. –  After waiting 2 minutes, unscrew nut and detach thrust sleeve in direction of travel.

–  Check that the outwardly visible sealing lip of the oil seal is resting on the cylindrical sealing surface of the pinion shaft and not on the chamfer -arrow-. Press in the oil seal further if necessary. –  Install flange shaft (right-side) → multitronic 01J, front-wheel drive; Rep. Gr.39, → multitronic 0AN, front-wheel drive; Rep. Gr.39. –  Fit the differential and the cover for the front final drive → Chapter.   Note t  When gearbox is removed: t  As it will be necessary to road-test the vehicle, the gearbox must be re-installed for the leak check → multitronic 01J, front-wheel drive; Rep. Gr.37, → multitronic 0AN, front-wheel drive; Rep. Gr.37. –  Fill up with ATF → Chapter.

–  Perform an extensive road test and then check for freedom from leaks at the breather hole -arrow A- at the cover for the front final drive.   Note t  On some gearboxes, the breather hole is covered by a guard plate. t  On new front final drive covers, the breather hole has been moved to the bottom screw -arrow- (internal oil duct). Leakage is then only visible at the bottom at the cover for the front final drive. l  Repair work must be repeated if oil emerges at breather hole.