Audi Workshop Service and Repair Manuals

Removing and installing centre differential housing with gearbox installed

Special tools and workshop equipment required

t	Engine and gearbox jack -V.A.G 1383 A-

t	Gearbox support -T10337-

t	Counterhold tool -T10172-

t	Adapter -T10172/5-

t	Used oil collection and extraction unit -V.A.G 1782-

t	Torque wrench -V.A.G 1331-

t	Safety goggles

Removing l  Gearbox in vehicle   Caution Risk of damage to the gearbox. The engine must not be run and the vehicle must not be towed without gear oil.   Note t  Refer to general repair instructions → Chapter. t  Note rules for cleanliness when working on automatic gearbox → Chapter.

–  Open quick-release fasteners -2 ... 4- and remove noise insulation (rear) → Rep. Gr.66.   Note -Arrow- can be disregarded.   Caution The flexible joint in the front exhaust pipe can be damaged. The flexible joint in the front exhaust pipe must not be bent further than 10°.

–  Vehicles with one front exhaust pipe: Disconnect exhaust system at clamp -arrow-.

–  Vehicles with two front exhaust pipes: Disconnect exhaust system at clamps -1- and -2-.

–  Remove bolts -arrows- and detach heat shield for propshaft.

–  Remove propshaft/gearbox connecting bolt. To do so, use counterhold tool -T10172- with -T10172/5-. –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie propshaft to side.   Caution There is a risk of damage to the gearbox oil pan. Do not place gearbox down on the gearbox oil pan. –  Support gearbox at tunnel cross member using engine and gearbox jack -V.A.G 1383 A- with gearbox support -T10337- attached.   WARNING Risk of accident. Engine and gearbox jack -V.A.G 1383 A- must remain in position when work is being carried out and must not be left unattended.

–  Remove bolts -arrows- for tunnel cross member.   Note The illustration does not show engine and gearbox jack -V.A.G 1383 A-.

–  Lower gearbox by dimension -a- using engine and gearbox jack -V.A.G 1383 A-. l  Dimension -a- = 100 mm (maximum)

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox.   WARNING Risk of eye injury. Wear safety goggles.   Note The gearbox does not have an oil drain plug. The gear oil can only be drained by removing the housing. –  Place cloth on tunnel cross member to prevent escaping oil from getting into gaps in tunnel cross member. –  Loosen and remove securing bolts for centre differential housing in the sequence -6 ... 1-; allow gear oil to drain out.   Caution Gearbox components must be handled with care, otherwise they will be damaged. Detach centre differential housing from gearbox carefully towards the rear. Take care that centre differential does not drop out of gearbox.

–  Secure centre differential -1- to prevent it from falling out, or pull it off output shaft towards rear.   Note Different versions of centre differential -1- depending on equipment version. Installing Installation is carried out in reverse sequence; note the following:   Note Renew O-ring for centre differential housing. If centre differential has been removed -1-: –  Fit centre differential onto splines of output shaft, at the same time turning centre differential slightly. –  Check whether centre differential can be turned by hand after being fitted. –  Fit housing onto centre differential with output shaft installed (turn housing slightly if necessary).

–  Tighten bolts for centre differential housing → Fig.. –  Clean and install tunnel cross member → Chapter. –  Install propshaft → Rear final drive 0BC; Rep. Gr.39 or → Rear final drive 0BD; Rep. Gr.39. –  Install exhaust system so it is free of stress and align → Rep. Gr.26 –  Fill up gear oil in transfer box → Chapter