Cap. III- LAS ACTITUDES LINGÜÍSTICAS
2.- HISTO RIA
5.1 Exploded view - centre differential
Caution
Risk of damage to gearbox
♦ Do not run the engine or tow the vehicle if the centre dif‐
ferential has been removed or if the gear oil has been drained.
1 - O-ring
❑ Renew
❑ Lubricate with gear oil 2 - Centre differential
❑ For ball bearing for flange shaft 5 - Circlip
❑ For flange shaft 6 - Ball bearing
❑ For flange shaft (rear)
❑ ⇒ “5.4 Renewing ball bearing for flange shaft (rear)”, page 116 7 - Screw plug
❑ For oil filler hole on transfer box
❑ 35 Nm
❑ Renew
8 - Centre differential housing
❑ ⇒ “5.2 Removing and in‐
stalling centre differen‐
tial”, page 110 9 - Oil seal for flange shaft
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10 - Flange shaft (rear)
❑ Removing and installing ⇒ “5.3 Renewing oil seal for flange shaft (rear)”, page 114
❑ Renew oil seal when renewing flange shaft (rear)
❑ Select correct components from ⇒ Electronic parts catalogue 11 - Bolt
❑ Tightening torque and sequence ⇒ page 109
❑ Renew
Centre differential housing - tightening torque and sequence – Tighten bolts for centre differential housing in three stages as
follows:
1. Tighten bolts -1- and -2- initially to 3 Nm.
2. Tighten bolts to 8 Nm in sequence -1 ... 6-.
3. Tighten bolts 90° further in the sequence -1 ... 6-.
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5.2 Removing and installing centre differential
Special tools and workshop equipment required
♦ Engine and gearbox jack -V.A.G 1383
A-♦ Gearbox support -
T10337-♦ Counterhold tool -
T10172-♦ Adapters -
T10172/5-♦ Used oil collection and ex‐
traction unit - V.A.G
1782-♦ Torque wrench - V.A.G
1331-♦ Safety goggles
Removing
• Gearbox in vehicle Caution
Risk of damage to gearbox
♦ The engine must not be run and the vehicle must not be towed without gear oil.
Note
♦ Refer to general repair instructions ⇒ page 5 .
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– Remove rear noise insulation -2- ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .
Note
-Arrow- can be disregarded.
Caution
Risk of damage to flexible joint in front silencer.
♦ The flexible joint in the front silencer must not be bent fur‐
ther than 10°.
– Unbolt clamps -1- and -2-, push clamps towards rear and tie up front silencers to side.
– If fitted, remove bolts -arrows- and detach heat shield for prop‐
shaft.
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– 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- .
• Dimension -a- = 100 mm (maximum)
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– Place used oil collection and extraction unit - V.A.G 1782- be‐
low 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 hous‐
ing 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.
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 turn centre differential slightly.
– Check whether centre differential can be turned by hand after being fitted.
– Fit housing onto centre differential with flange shaft (rear) in‐
stalled. Turn housing slightly if necessary.
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– Tighten bolts for centre differential housing ⇒ page 109 . – Clean and install tunnel cross member ⇒ page 61 .
– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Exploded view - propshaft .
– Install exhaust system and perform stress-free alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silenc‐
ers .
– Fill up gear oil in transfer box ⇒ page 96
5.3 Renewing oil seal for flange shaft (rear)
Special tools and workshop equipment required
♦ Thrust plate - VW
401-♦ Thrust plate - VW
402-♦ Press tool - VW
409-♦ Press tool - VW
412-♦ Base plate - VW
441-♦ Thrust piece -
T40190-Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
Procedure
– Remove centre differential housing ⇒ page 110 . – Remove circlip -arrow- on inside of housing.
Note
The circlip locates the flange shaft on the bearing in the housing.
– Press flange shaft -A- out of centre differential housing using press tool - VW 409- . To do so, place housing onto thrust plate - VW 401- and thrust plate - VW 402- .
Note
Hold flange shaft -A- with one hand to prevent if falling.
– Pry out oil seal.
Note
To prevent damage to the housing, place something underneath (e.g. metal bar -A-).
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Installing
– Lightly lubricate outer circumference of oil seal with gear oil.
• Installation position: the open side of the oil seal faces the housing.
– Drive in new oil seal as far as stop using thrust piece -T40190- . Make sure oil seal remains straight.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Press flange shaft -A- into centre differential housing using base plate - VW 441- and press tool - VW 412- . To do so, place housing onto thrust plate VW 401 and thrust plate -VW 402- .
Note
Only insert flange shaft as far as necessary to install circlip.
– Fit circlip -arrow- into groove on flange shaft.
– Install centre differential housing ⇒ page 110 . – Fill up gear oil in transfer box ⇒ page 96
5.4 Renewing ball bearing for flange shaft (rear)
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Special tools and workshop equipment required
♦ Thrust plate - VW
401-♦ Thrust plate - VW
402-♦ Press tool - VW
412-♦ Tube -
2040-♦ Tube - VW 415
A-Procedure
– Remove centre differential housing ⇒ page 110 .
– Remove circlip -A- for flange shaft (rear), flange shaft (rear) and oil seal for flange shaft (rear) ⇒ page 114 .
– Remove circlip -B- for ball bearing.
Note
Shown in illustration with flange shaft (rear) and circlip for flange shaft (rear) -A- still installed.
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Pressing out ball bearing for flange shaft
Pressing in ball bearing for flange shaft
• Collar of tube - VW 415 A- -arrow- faces press tool - VW 412- .
5.5 Renewing ball bearing for centre differential
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Special tools and workshop equipment required
♦ Thrust plate - VW
401-♦ Thrust plate - VW
402-♦ Press tool - VW
412-♦ Press tool - VW
432-♦ Assembly tool -
3350-♦ Splitter 22 ... 115 mm - Kuk‐
ko
17/2-Procedure
– Remove centre differential housing ⇒ page 110 .
– Pull centre differential -1- off output shaft towards the rear.
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Pressing ball bearing off centre differential A - Splitter 22 ... 115 mm - Kukko
17/2-The collar of press tool - VW 432- points towards ball bearing.
Pressing ball bearing onto centre differential
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6 Gearbox control system
⇒ “6.1 Overview of fitting locations - gearbox control system”,