Audi Workshop Service and Repair Manuals

Renewing oil seal for propshaft flange Special tools and workshop equipment required

t  Drive flange installing tool -VW 391-

t  Adapter -VW 771/40- from multi-purpose tool set -VW 771-

t  Counterhold tool -3028-

t  Puller -T10055- t  -2-Adapter -T10055/2-

t  Thrust piece -T40109-

t  Assembly sleeve -T40222/1- t  Sealing grease -G 052 128 A1- t  Bolts (2x) M 8 x 30 t  Bolts (1x) M 8 x 45

Removing l  Rear final drive installed l  Refer to general repair instructions → Chapter. –  Disconnect exhaust system at clamps -1- and -2-. –  Remove rear section of exhaust system → Rep. gr.26.   Note A second mechanic is required for removing the rear section of the exhaust system.

–  Unscrew gear oil drain plug -arrow- and drain off approx. 250 ml of gear oil. –  Screw in and tighten drain plug -arrow-. l  Tightening torque: 30 Nm

–  Detach propshaft from rear final drive → Chapter. Audi A8 –  Guide propshaft downwards between fuel tank and rear subframe and tie up on one side.

Audi A4, A5 Coupé, A5 Sportback, A5 Cabriolet, Q5, A6, A7 –  If fitted, remove front cross member -2- and rear cross member -3-. –  Remove heat shield -1-.

–  Remove bolts -arrows- securing centre propshaft bearing. –  Lower propshaft at centre bearing. –  When doing so, guide propshaft downwards between fuel tank and rear subframe. –  Fit bolts -arrows- for centre bearing and hand-tighten. –  Tie propshaft to one side.

Continued for all vehicles –  Remove high-temperature grease in propshaft flange on rear final drive. –  Remove circlip -arrow-.   Caution Renew circlip with new circlip of same thickness if overstretched or damaged during removal. For correct version, refer to → Electronic parts catalogue.

–  Mark position of flange -B- for propshaft relative to pinion shaft -A--arrow-.   Note t  This marking -arrow- is necessary in order to maintain the original position of the coloured dot -C- on the outside of the flange. t  This is the only effective way to minimise the imbalance in the rear final drive.

–  Screw 2 bolts M 8 x 30-arrow- into flange. –  Pull off propshaft flange using drive flange installing tool -VW 391-.

–  Lay absorbent cloth -A- on subframe under final drive.

–  Pierce metal ring of oil seal -A- in direction of -arrow - using e.g. a scriber -B-.

–  Then screw self-tapping screw -arrow- into this hole in oil seal -A-.

–  Pull out oil seal -A- for propshaft flange in direction of -arrow-. -B- Self-tapping screw

Installing Perform installation in reverse sequence of removal. Note the following: –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Fit new oil seal -A- on assembly sleeve -T40222/1-.   Note Check that spring of oil seal behind sealing lip is in installation position. –  Lightly lubricate outer circumference of oil seal with gear oil. –  Fit assembly sleeve -T40222/1- onto pinion shaft -B- together with oil seal -A-. –  Push oil seal -A- in as far as it will go. –  Remove assembly sleeve -T40222/1-.

–  Drive in new oil seal onto stop (take care to keep oil seal straight).

–  Position propshaft flange -B- on pinion shaft -A- so that markings -arrow- are in line.

–  Screw adapter -VW 771/40- into threaded hole in pinion shaft. –  Attach counterhold tool -3028- to flange for propshaft with bolts (M 8 x 30) -arrows A-. –  Secure installing tool -VW 391- with bolt (M 8 x 45) -arrow B-. At the same time, screw spindle of installing tool into adapter -VW 771/40-. –  Pull in flange for propshaft as far as stop (counterhold spindle of installing tool with spanner).

Install circlip -1- as follows: l  Chamfer on inner diameter of circlip -arrow A- must face outwards towards propshaft. l  If provided, the wider lug on the circlip -arrow B- must be on the right side, as shown in the illustration. When renewing flange for propshaft, please note that: l  The thickness of the circlip -1- must be re-determined. l  To do so, determine the thickest circlip -1- that will just fit in the groove and install it. For part number refer to → Electronic parts catalogue.

–  Attach propshaft to rear final drive → Anchor. Audi A4, A5 Coupé, A5 Sportback, A5 Cabriolet, Q5, A6, A7 –  Secure centre propshaft bearing to body so it is free of stress. Tightening torque → Item –  Install heat shield and cross member → General body repairs, exterior; Rep. gr.66. Continued for all vehicles –  Top up gear oil in rear final drive → Chapter. –  Install rear section of exhaust system → Rep. gr.26.