Audi Workshop Service and Repair Manuals

Renewing flange shaft oil seal (left-side) with gearbox removed Special tools and workshop equipment required

t  Drift -VW 295-

t  Puller -T10037-

t  Thrust piece -T40164-

t  Drip tray for workshop hoist -VAS 6208- t  Sealing grease -G 052 128 A1- Removing l  Gearbox removed → 6-speed manual gearbox 0B4, four-wheel drive; Rep. Gr.39

Place drip tray -VAS 6208- under the gearbox. –  Open plug -arrow- and drain off gear oil. –  Re-fit and tighten plug -arrow-. Tightening torque → Item

–  Unscrew bolts -arrows- on mounting bracket for flange shaft (left-side).

–  Remove flange shaft from gearbox in direction of -arrow A-.   Note

t  If the flange shaft (left-side) cannot be removed by hand, pull it out carefully using multi-purpose tool -VW 771-. t  To do this, secure plate of puller -T10037- to flange shaft -arrows- and attach plate to spindle of multi-purpose tool -VW 771- (nuts -A-).

–  Remove flange shaft (right-side); to do so, secure puller -T10037- to cover for final drive -arrow-.

–  Remove bolts -arrows-.   Caution Risk of damage to the differential. t  Detach cover for front final drive slowly and carefully from gearbox housing. The differential may otherwise fall out of the gearbox. t  The differential must not be re-installed if it is damaged. Renew the gearbox if the differential is damaged. –  Carefully detach cover for front final drive (some remaining gear oil will drain off).

–  Carefully remove differential -arrow- and set it down on a soft surface. –  Lever out oil seal for flange shaft (left-side). –  Thoroughly clean opening leading to gearbox housing.

Installing Installation is carried out in reverse sequence; note the following: –  Lightly oil outer circumference of new oil seal and slide onto thrust piece -T40164-. l  Open side of oil seal faces towards thrust piece -T40164-. –  Drive in oil seal onto stop (take care to keep seal straight). –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.

–  Fit differential. –  Install cover for final drive with new O-ring and tighten bolts -arrows-. Tightening torque → Item

–  Always renew circlip -A- for flange shaft (right-side). –  Clamp flange shaft in vice, using jaw protectors. Use new circlip -A- to press old circlip out of groove in flange shaft. –  Drive in flange shaft (right-side) with drift -VW 295-.

–  Turn clutch module -1- so that you can see opening to differential -arrow 3-. –  Thoroughly clean flange shaft (left-side) -2-. –  Slide flange-shaft (left-side) -2- into gearbox in direction of -arrow B- (keep end of shaft centered while guiding it into oil seal on front final drive -arrow 3-).   Caution Risk of damage to oil seal. t  If you do not keep the shaft centered, the splines of the shaft -2- will damage the oil seal -arrow 3- between the differential and the gearbox housing. t  If oil seal is damaged, it must be renewed → Chapter.

–  Clean threads of bolts -arrows- with a wire brush. Then install bolts with locking fluid -AMV 185 101 A1- and secure mounting bracket for flange shaft (left-side) (specified torque → Item). –  Fill up with gear oil and check oil level in manual gearbox → 6-speed manual gearbox 0B4, four-wheel drive; Rep. Gr.34.