Audi Workshop Service and Repair Manuals

Removing and installing centre differential housing with gearbox installed - bolted propshaft Special tools and workshop equipment required

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

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

t  Counterhold tool -T10172- with -T10172/5-

t  Gearbox support -T10337- t  For sealant, refer to → Electronic parts catalogue

Removing –  Remove rear noise insulation -2- → General body repairs, exterior; Rep. gr.66.

Vehicles with single exhaust system:   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°. –  Unscrew bolts -arrows-, push clamp towards rear and tie up front exhaust pipe to body.

Vehicles with twin exhaust system:   Caution The flexible joint in the front silencer can be damaged. The flexible joint in the front silencer must not be bent further than 10°. –  Unbolt clamps -1- and -2-, push clamps towards rear and tie up front silencers to body.

A5 Cabriolet/Sportback: –  Remove diagonal struts (left and right) → Running gear, front-wheel drive and four-wheel drive; Rep. gr.42.

Continued for all vehicles: –  Remove subframe cross brace → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40.   Caution Risk of damage to parts of the running gear. Do not let the vehicle down on the wheels if the gearbox mounting, steering box and subframe cross brace are not properly installed.

–  If fitted, remove bolts -arrows- and detach heat shield -1- for propshaft.

–  Remove bolts from connection between propshaft and gearbox (counterhold using counter-hold tool -T10172- with -T10172/5-). –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially. –  Tie propshaft up to underbody.

–  Set up gearbox support -T10337- on engine and gearbox jack -V.A.G 1383 A- and position underneath gearbox mounting. –  Slightly lift gearbox with engine and gearbox jack -V.A.G 1383 A-.   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.

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

–  Unscrew nuts -arrows- and remove tunnel cross member.

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Remove bolts -1 … 4- and carefully detach centre differential housing; gear oil (MTF) will drain off.   Caution Risk of damage to the centre differential. t  Pull the centre differential housing slowly and carefully towards the rear off the gearbox. The centre differential may otherwise fall out of the gearbox. t  A centre differential which has fallen to the ground can no longer be installed.

If bearing plate -1- remains behind in centre differential housing, proceed as follows:   Caution Risk of damage to the sealing surface of the centre differential housing. Carefully tap the housing in several places with a hammer. –  Grip one of the side ribs on bearing plate -1- with pliers and pull off in direction of -arrow A-. –  While doing so, carefully tap alternate sides of housing -arrows B- with a rubber-headed hammer. Installing Installation is carried out in reverse sequence; note the following: l  Tightening torques → Chapter „Exploded view - centre differential housing - bolted propshaft“   Note Renew the bolts for the centre differential housing. –  Thoroughly clean both housing joint surfaces; they must be free from oil and grease.

–  Apply bead of sealant -arrow 1- evenly and not too thick on housing joint surface; for sealant refer to → Electronic parts catalogue. –  To avoid contact corrosion, apply a ring of sealant around each bolt hole -arrow 2-. –  Lightly lubricate fitting surfaces for bearing plate with gear oil (MTF).

–  Check that spacer sleeve -2- and shim -1- are fitted on output shaft.

–  Lightly lubricate surfaces of both races on outside of bearing plate with a small quantity of gear oil (MTF). –  Insert bearing plate. l  Installation position: shoulder of bearing plate -arrow A- must engage in recess on gearbox housing -arrow B-.

–  Fit centre differential -2- onto gearbox -1-. –  Insert spring -3- in centre differential. –  Apply a small quantity of grease to dished spring -5- and shim(s) -4- and secure in place in centre differential housing -6-. l  Installation position of dished spring: convex side (which curves outwards) faces rear flange shaft.

–  Press centre differential housing fully onto gearbox housing, keeping it centred, and hold in place. –  Tighten bolts for centre differential housing → Fig..

–  Install tunnel cross member and tighten → Chapter.   Note Please refer to the vehicle data sticker or the identification on the rear final drive to find out which type of rear final drive is installed in the vehicle. Then select the appropriate Workshop Manual for the rear final drive. –  Bolt propshaft onto gearbox → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BF and 0BE - sport differential; Rep. gr.39. –  → Chapter „Filling up gear oil (MTF)“. –  Install exhaust system so it is free of stress → Engine, mechanics; Rep. gr.26. –  Install subframe cross brace → Running gear, front-wheel drive and four-wheel drive; Rep. gr.40. –  Install diagonal struts → Running gear, front-wheel drive and four-wheel drive; Rep. gr.42. –  Install noise insulation → General body repairs, exterior; Rep. gr.66.