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38-Service Manual Rear Final Drive 01R

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0% found this document useful (0 votes)

169 views102 pages

38-Service Manual Rear Final Drive 01R

Uploaded by

rockrapdude

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Service

Workshop Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
Audi A6 2005 ➤
Audi A8 2003 ➤
Rear final drive 01R
Edition 02.2010
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.

Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - Technical data
39 - Final drive - rear differential

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Audi AG, Ingolstadt A005A600920

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Rear final drive identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Audi A4 2001 ▸ – Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . 3
2.2 Audi Cabriolet 2003 ▸ – Code letters, allocation, transmission ratios, capacities . . . . . . . . 4
2.3 Audi A6 2005 ▸ – Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . 4
2.4 Audi A8 2003 ▸ – Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . 5
3 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Jacking mode (vehicles with pneumatic suspension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Servicing propshaft - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing and installing propshaft on Audi A4, Audi Cabriolet and Audi A6 . . . . . . . . . . . . 12
1.2 Removing and installing propshaft on Audi A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Detaching and attaching propshaft at rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Measuring and marking radial run-out at flange for propshaft . . . . . . . . . . . . . . . . . . . . . . 30
3 Checking gear oil in rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6 . . . . . . . . . . . . . . 32
4.1 Removing rear final drive on Audi A4, Audi Cabriolet and Audi A6 . . . . . . . . . . . . . . . . . . 32
5 Exploded view - rear final drive on Audi A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Removing and installing rear final drive on Audi A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6 Renewing flange shaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.1 Renewing flange shaft oil seals on Audi A4, Audi Cabriolet . . . . . . . . . . . . . . . . . . . . . . . . 42
6.2 Renewing flange shaft oil seals on Audi A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.3 Renewing flange shaft oil seals on Audi A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7 Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) . . . . . . 55
8 General overview - dismantling and assembling rear final drive . . . . . . . . . . . . . . . . . . . . 60
9 Exploded view - removing and installing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.1 Removing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 Exploded view - dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11 Exploded view - removing and installing pinion shaft; dismantling and assembling pinion
shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.1 Removing and installing pinion shaft; dismantling and assembling pinion shaft . . . . . . . . 75
12 Adjusting pinion shaft and crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12.1 Adjustment and marking of final drive gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12.2 Position of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
12.3 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
12.4 Recommended sequence for adjusting gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12.5 Adjusting pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12.6 Adjusting crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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.

Contents i
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

ii Contents
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

00 – Technical data
1 Rear final drive identification

Note

When installing a new rear final drive unit, it is important to verify

not only the code letters of the final drive but also the PR No. and
the engine code of the vehicle in the ⇒ Electronic parts catalogue .
This is necessary to ensure that the correct version is installed.

The rear final drive 01R is installed in conjunction with the follow‐
ing gearbox types:
♦ 5-speed manual gearbox 01A, four-wheel drive
♦ 6-speed manual gearbox 01E, four-wheel drive
♦ 6-speed manual gearbox 02X, four-wheel drive
♦ 6-speed manual gearbox 0A3, four-wheel drive
♦ Automatic gearbox 01V, four-wheel drive
♦ Automatic gearbox 09E, four-wheel drive
♦ Automatic gearbox 09L, four-wheel drive
Allocation
⇒ “2.1 Audi A4 2001 ▸ – Code letters, allocation, transmission
ratios, capacities”, page 3
Allocation
⇒ “2.2 Audi Cabriolet 2003 ▸ – Code letters, allocation, transmis‐
sion ratios, capacities”, page 4
Allocation
⇒ “2.3 Audi A6 2005 ▸ – Code letters, allocation, transmission
ratios, capacities”, page 4
Allocation
⇒ “2.4 Audi A8 2003 ▸ – Code letters, allocation, transmission
ratios, capacities”, page 5
Location
Protected on Copying
by copyright. rear final drive
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
Code
with respectletters and date
to the correctness of manufacture
of information -arrow
in this document. 1-by AUDI AG.
Copyright

Final drive 01R -arrow 2-

1. Rear final drive identification 1

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Final drive 01R -arrow 2-

Code lettersProtected
and date of manufacture for rear final drive
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
Example: FGLto the correctness
with respect 15 of information
12 03 Copyright by AUDI AG.
in this document.

I I I I
Code letters Day Month Year -2003-
of manufacture
Other information can be disregarded.

2 Rep. Gr.00 - Technical data

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

2 Code letters, allocation, transmission

ratios, capacities
♦ ⇒ “2.1 Audi A4 2001 ▸ – Code letters, allocation, transmission
ratios, capacities”, page 3
♦ ⇒ “2.2 Audi Cabriolet 2003 ▸ – Code letters, allocation, trans‐
mission ratios, capacities”, page 4
♦ ⇒ “2.3 Audi A6 2005 ▸ – Code letters, allocation, transmission
ratios, capacities”, page 4
♦ ⇒ “2.4 Audi A8 2003 ▸ – Code letters, allocation, transmission
ratios, capacities”, page 5

2.1 Audi A4 2001 ▸ – Code letters, alloca‐

tion, transmission ratios, capacities
The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Date of manufacture
♦ Allocation to engine and manual or automatic gearbox ac‐
cording to code letters and PR numbers
Rear final drive 01R
Code letters ETQ ETR ETS
Ratio Final drive 37 : 9 = 4.111 37 : 9 = 4.111 35 : 9 = 3.889
Z2 : Z1
Capacity 1.5 litres
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Drive shaft flange ∅ 75.5 mm 70.7 mm 75.5 mm

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
Rear final drive 01R in this document. Copyright by AUDI AG.
with respect to the correctness of information
Code letters ETT EUB EXZ
Ratio Final drive 35 : 9 = 3.889 37 : 10 = 3.700 35 : 9 = 3.889
Z2 : Z1
Capacity 1.5 litres
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Drive shaft flange ∅ 70.7 mm 75.5 mm 75.5 mm

Rear final drive 01R

Code letters FUB GDF HCC
Ratio Final drive 35 : 8 = 4.375 31 : 10 = 3.100 31 : 10 = 3.100
Z2 : Z1
Capacity 1.5 litres
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Drive shaft flange ∅ 75.5 mm 75.5 mm 75.5 mm

2. Code letters, allocation, transmission ratios, capacities 3

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

2.2 Audi Cabriolet 2003 ▸ – Code letters, al‐

location, transmission ratios, capacities
The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Date of manufacture
♦ Allocation to engine and manual or automatic gearbox ac‐
cording to code letters and PR numbers
Rear final drive 01R
Code letters ETS EXZ GDF
Ratio Final drive 35 : 9 = 3.889 35 : 9 = 3.889 31 : 10 = 3.100
Z2 : Z1
Capacity 1.5
Protected by copyright. Copying for litres
private or commercial purposes, in part or in whole, is not
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

tion Gear oil G 052 145 S2 (container size 1.0 litre)

with respect to the correctness of information in this document. Copyright by AUDI AG.

Drive shaft flange ∅ 75.5 mm 75.5 mm 75.5 mm

2.3 Audi A6 2005 ▸ – Code letters, alloca‐

tion, transmission ratios, capacities
The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Date of manufacture
♦ Allocation to engine and manual or automatic gearbox ac‐
cording to code letters and PR numbers
Rear final drive 01R
Code letters ETQ ETS FGL
Ratio Final drive 37 : 9 = 4.111 35 : 9 = 3.889 32 : 9 = 3.556
Z2 : Z1
Capacity 1.5 litres
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Drive shaft flange ∅ 75.5 mm 75.5 mm 75.5 mm

Rear final drive 01R

Code letters FUB GSZ HCC
Ratio Final drive 35 : 8 = 4.375 32 : 9 = 3.556 31 : 10 = 3.100
Z2 : Z1
Capacity 1.5 litres
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Drive shaft flange ∅ 75.5 mm 75.5 mm 75.5 mm

4 Rep. Gr.00 - Technical data

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

2.4 Audi A8 2003 ▸ – Code letters, alloca‐

tion, transmission ratios, capacities
The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Date of manufacture
♦ Allocation to engine and manual or automatic gearbox ac‐
cording to code letters and PR numbers
Rear final drive 01R
Code letters EYC GMZ GZG
Ratio Final drive 31 : 10 = 3.100 32 : 9 = 3.556 32 : 9 = 3.556
Z2 : Z1
Capacity 1.5 litres
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Drive shaft flange ∅ 108 mm 108 mm 108 mm

Rear final drive 01R

Code letters HCL HWA HWB
Ratio Final drive 31 : 10 = 3.100 31 : 10 = 3.100 32 : 9 = 3.556
Z2 : Z1
Capacity 1.5 litres
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Drive shaft flange ∅ 108 mm 108 mm 108 mm

Rear final drive 01R

Code letters JSR
Manufactured from 06.06
to 09.06
Ratio Final drive 32 : 9 = 3.556
Z2 : Z1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Capacity
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 1.5 litres
with respect to the correctness of information in this document. Copyright by AUDI AG.
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Drive shaft flange ∅ 108 mm
Select correct unit by checking engine, manual gearbox and automatic gearbox versions in ⇒ Electronic
parts catalogue .

2. Code letters, allocation, transmission ratios, capacities 5

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

3 Transmission layout
♦ Illustrated with 6-speed manual gearbox 0A3, four-wheel drive
Identification

Note

Arrows point in direction of travel

1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft (main shaft)
5 - Front differential
6 - Front pinion shaft (output
shaft)
7 - Hollow shaft
8 - Centre differential
9 - Propshaft
10 - Rear pinion shaft
11 - Rear differential

Ratio

Note

Arrows point in direction of travel

6 Rep. Gr.00 - Technical data

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A1 - Final drive (front)
A2 - Final drive (rear)

3. Transmission layout 7
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

4 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs. The usual basic safety precau‐
tions also naturally apply when carrying out repair work.
A number of generally applicable instructions for the various re‐
pair procedures are summarised here under the designation
“Components” ⇒ page 8 . They apply to the work described in
this Manual.

4.1 Contact corrosion!

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con‐
ductive materials.
If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts: these
have been fully tested and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.
♦ Damage caused by contact corrosion is not covered under
warranty.

4.2 Jacking mode (vehicles with pneumatic

suspension)
Before raising the vehicle on a 2-column lifting platform (wheels
off the ground) you must first activate the jacking mode ⇒ Rep.
Gr. 43 .

4.3 Special tools

For a complete list of special tools used in this Workshop Manual
⇒ "Special tools, Workshop equipment"

4.4 Components
Rear final drive
♦ Allocate bolts and other components according to final drive
code letters, refer to ⇒ Electronic parts catalogue .
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
♦ When installing a new rear final drive unit, check the oil level
with respect to the correctness of information in this document. Copyright by AUDI AG.

in the final drive and top up if necessary ⇒ page 31 .

♦ Capacity and specification ⇒ page 3
♦ When installing mounting brackets as well as other waxed
components, the contact surfaces must be cleaned. The con‐
tact surfaces must be free of wax and grease.
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.

8 Rep. Gr.00 - Technical data

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

O-rings, oil seals and gaskets

♦ Always renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrow-
about half full with grease -G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Lightly lubricate O-rings before installation to prevent them
from being trapped and damaged during assembly.
♦ After renewing seals and gaskets, check and, if necessary, top
up oil level in final drive ⇒ page 31 .
Locking elements

4. General repair instructions 9

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Do not over-stretch circlips.

♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.
Nuts, bolts
♦ Nuts and bolts for securing covers and housings must be
slackened and tightened in diagonal sequence.
♦ Loosen and tighten particularly sensitive parts in diagonal se‐
quence and in stages, taking care to keep them straight.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and nuts.
♦ Clean the threads of bolts which are secured with locking fluid
using a wire brush (does not apply to propshaft bolts: these
must be renewed). Then apply locking fluid -AMV 185 101 A1-
to bolt threads before installing.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
Bearings
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Always renew the tapered roller bearings on one shaft togeth‐
er as a set and use new bearings from a single manufacturer.
♦ Lubricate bearing seats lightly with gear oil before pressing
bearings onto shafts.
♦ Lubricate bearing seats lightly with gear oil before installing
bearings and outer bearing races in final drive housing.
♦ Heat inner races to approx. 100° C before installing.
♦ Do not interchange the outer or inner races of bearings of the
same size (the bearings are paired).
Shims
♦ Use a micrometer to measure the shims at several points.
Tolerance variations make it possible to obtain the exact shim
thickness required.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Check for burrs and damage. 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.
♦ Do not install shims which are damaged or not in perfect con‐
dition.

10 Rep. Gr.00 - Technical data

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

39 – Final drive - rear differential

1 Servicing propshaft - overview

Note

♦ Refer to general repair instructions ⇒ page 8 .

♦ No repair work can be carried out on the propshaft with the
exception of removing, installing and adjusting.
♦ The propshaft should normally be kept straight when it is stor‐
ed or transported.
♦ The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint
or the protective boot can be damaged if the joint is forced
against its stop.
♦ The propshaft must be tied up or supported at one end if it is
detached only at the gearbox or at the rear final drive. If nec‐
essary, the propshaft can be bent as far as the stop at the
centre joint, but it must not be subjected to force.
♦ Before removing, mark the positions of all parts in relation to
each other. Reinstall in the same position to avoid excessive
imbalance, resulting in bearing damage and rumbling noise.
♦ Use counterhold tool -T10172- with adapters -T10172/5- to
slacken and tighten the propshaft bolts. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ After detaching the propshaft from the rear final drive, the ad‐
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.
ditional balancing washer (thicker washer) that may be fitted
between the lock plate and the bolt head (hexagon socket bolt)
must not be reinstalled.
♦ If problems occur (noise or vibration), ensure that the centre
bearing is free of stress and check the radial runout of the
propshaft flange at the rear final drive before renewing the
propshaft ⇒ page 30 .

1. Servicing propshaft - overview 11

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

1 - Rear final drive

❑ Removing and installing
on Audi A4, Audi Cab‐
riolet and Audi A6
⇒ page 32
❑ Removing and installing
on Audi A8
⇒ page 37
2 - Gasket
❑ Renew
❑ Pull off protective foil
❑ Degrease flange shaft
and glue on gasket
3 - Propshaft
❑ Removing and installing
on Audi A4, Audi Cab‐
riolet and Audi A6
⇒ page 12
❑ Removing and installing
on Audi A8
⇒ page 19
4 - Balancing washer
❑ Not fitted on all vehicles
❑ May be fitted between
one socket head bolt
⇒ Item 5 (page 12)
and one lock plate
⇒ Item 6 (page 12) at
rear final drive
❑ If fitted, this balancing
washer must not be re-
installed after the prop‐
shaft has been detach‐
ed from the rear final
drive.
5 - Hexagon socketProtected
head by bolt, 55 Nm
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
❑ Self-locking with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Always renew
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ The tapped holes for the bolts in the flange shafts must always be cleaned (e.g. with a thread tap)
❑ Use counterhold tool -T10172- with adapters -T10172/5- to slacken and tighten
6 - Lock plate
7 - Centre bearing
8 - Hexagon bolt, 25 Nm
9 - Gearbox

1.1 Removing and installing propshaft on

Audi A4, Audi Cabriolet and Audi A6
Special tools and workshop equipment required

12 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Assembly tool -3139-

♦ Removal lever -80 - 200-

♦ Counterhold tool -T10172- with adapters -T10172/5-

♦ Engine and gearbox jack -V.A.G 1383 A- with universal gear‐

box support -V.A.G 1359/2-

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

♦ Please refer to notes ⇒ page 11 .

with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Repairs on the propshaft should be carried out on a two pillar

hoist.

1. Servicing propshaft - overview 13

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Disconnect exhaust system at clamps -arrows-.

– If fitted, remove rear cross piece -1-.

– Remove rear section of exhaust system -2- behind clamps ⇒
Rep. Gr. 26 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Audi A6:unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Detach heat shield -3- from vehicle underbody -arrows-.

Audi A4 and Audi Cabriolet:

– Lever off fasteners -A- for heat shield above centre bearing.
– Unscrew securing bolts for centre bearing -B-. Support the
propshaft by hand during this procedure.
– Remove heat shield with propshaft supported.
– Fit securing bolts for centre bearing -B- again and hand-tight‐
en.

Continued for all vehicles:

– Remove bolts securing front exhaust pipes -1- and -2-. Secure
front exhaust pipes to side of underbody.

Note

The flexible pipe connection (de-coupling element) on the front

exhaust pipe must not be bent more than 10° – otherwise it can
be damaged.

14 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Detach heat shield -A- from gearbox -arrows-.

– Check whether there is a factory marking (coloured dot)

-arrows A and B- on the propshaft flange and on the rear final
drive flange.
– If not, mark position of propshaft flange -arrow A- in relation to
rear final drive flange -arrow B- with paint marker.

– Attach assembly tool 3139 and tighten plastic nuts.

Note

Do not fit assembly tool onto balance plates.

– Remove bolts -arrows- securing centre bearing.

1. Servicing propshaft - overview 15

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Remove bolts from connection between propshaft and gear‐

box (counterhold using counterhold tool -T10172- with -
T10172/5- ).
– Remove propshaft from gearbox and support propshaft with
engine and gearbox jack -V.A.G 1383 A- .

– Remove bolts -1- (6x) on rear CV joint.

– Use counterhold tool -T10172- with adapters -T10172/5- .
– Remove the propshaft.

Note

The propshaft must be kept straight when it is stored or transpor‐

ted.

Installing propshaft on Audi A4 and Cabriolet and on Audi A6

Perform installation in reverse sequence of removal. Note the fol‐
lowing:

♦ Remove old, dried-out high-temperature grease from CV joints

and flanges for propshaft. Put in exactly the same quantity of
fresh high-temperature grease -G 052 133 A2- .
♦ Clean all remaining locking fluid out of the tapped holes in the
propshaft flange shafts on the gearbox and rear final drive. The
threads can be cleaned with a thread tap. Otherwise the se‐
curing bolts can shear off when they are screwed in.
♦ After detaching the propshaft from the rear final drive, the ad‐
ditional balancing washer (thicker washer) that may be fitted
between the lock plate and one of the securing bolts must not
be reinstalled.
♦ Always install new securing bolts for propshaft (self-locking
bolts).
♦ Note correct position of propshaft: the central CV joint is loca‐
ted behind the centre bearing and towards the rear final drive.
♦ Make sure that the marks on the propshaft flange -arrow A-
and on the gearbox/final drive flange -arrow B- are in line.
♦ If a new propshaft is being installed and the factory marking
on the rear final drive flange is no longer visible, the radial run-
out at the flange for the propshaft must be measured
⇒ page 30 , and the coloured marking on the new propshaft
must be aligned with the new marking on the flange.
– Gaskets for propshaft on flanges of gearbox and rear final
drive must be renewed. Degrease sealing surfaces and glue
on new gaskets.

16 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Bring propshaft into position and fit new bolts at rear final drive
-arrows- and at gearbox.

– Screw in securing bolts -arrows- so that centre bearing can still

be moved.

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
– Tighten bolts -1- securing propshaft on rear final drive to speci‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

fied torque ⇒ Item 5 (page 12) .

– Use counterhold tool -T10172- with adapters -T10172/5- .

– Tighten bolts securing propshaft (front end) to specified setting

⇒ Item 5 (page 12) .
– Use counterhold tool -T10172- with adapters -T10172/5- .
– Remove assembly tool -3139- .

1. Servicing propshaft - overview 17

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Audi A4 and Audi Cabriolet:

– Remove securing bolts -arrows-. The propshaft must be sup‐
ported by a second mechanic during this procedure.

– Install heat shield -2- (continue to support propshaft).

– Fit securing bolts -4- on left and right again and screw in a few
turns.
– Secure heat shield -2- on centre bearing -3- with one bolt on
each side -1- (M8 x 30).

Note

The centralising lug -arrow A- must fit in the locating hole

-arrow B- when tightening the bolt with washer -4-.

– Secure centre propshaft bearing to body so it is free of stress

and tighten -2-. Tightening torque ⇒ Item 8 (page 12)
– Remove locating bolts -1-.
– Insert retaining clips for heat shield. 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.

Audi A6:
– Secure centre propshaft bearing to body so it is free of stress
and tighten. The centralising lugs on the centre bearing mount‐
ing must fit in the locating holes -arrows-. Tightening torque
⇒ Item 8 (page 12)

18 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Secure heat shield -3- to vehicle underbody -arrows-.

Continued for all vehicles:

– Secure heat shield -A- on gearbox -arrows-.

– Where required, secure front exhaust pipes -1- and -2-.

– Install rear section of exhaust system -2- ⇒ Rep. Gr. 26 .

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
– Where fitted, install rearwith
cross piece -1- ⇒ Rep. Gr. 40 .
respect to the correctness of information in this document. Copyright by AUDI AG.

Tightening torque
Component Nm
Heat shield for propshaft to gearbox 25

1.2 Removing and installing propshaft on

Audi A8
Special tools and workshop equipment required

1. Servicing propshaft - overview 19

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Assembly tool -3139-

♦ Counterhold tool -T10172- with adapters -T10172/5-

♦ Engine and gearbox jack -V.A.G 1383 A- with universal sup‐

port -V.A.G 1359/2-

Removing propshaft

Note

♦ Observe notes ⇒ page 11 .

♦ Repairs on the propshaft should be carried out on a two pillar
hoist.

20 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Disconnect exhaust system at clamps -1- and -2-.

– Remove both cross pieces -A- and -B-.

– Remove rear section of exhaust system -C- ⇒ Rep. Gr. 26 .

– Remove heat shield -arrows-.

– Remove bolts -arrows- and secure main catalytic converters

to side of underbody.

Note

The flexible pipe connection (de-coupling element) on the front

exhaust pipe must not be bent more than 10° – otherwise it can
be damaged.
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.

1. Servicing propshaft - overview 21

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Unbolt heat shield -A- from gearbox -arrows-.

– If fitted, remove cover for rear final drive -arrows A and B-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check whetherpermitted
thereunless
is a authorised
factory by marking (coloured
AUDI AG. AUDI dot)
AG does not guarantee or accept any liability
-arrows A and B-withon the topropshaft
respect flange
the correctness and on
of information the
in this rear final
document. Copyright by AUDI AG.
drive flange.
– If not, mark position of propshaft flange -arrow A- in relation to
rear final drive flange -arrow B- with paint marker.

– Attach assembly tool -3139- with -3139/4- , and tighten the

plastic nuts.

Note

Do not fit assembly tool onto balance plates.

22 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Remove bolts -arrows- securing centre bearing.

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
– Remove bolts from connection between propshaft and gear‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

box (counterhold using counterhold tool -T10172- with -

T10172/5- ).
– Remove propshaft from gearbox and support propshaft with
engine and gearbox jack -V.A.G 1383 A- .

– Remove bolts -1- (6x) on rear CV joint.

– Use counterhold tool -T10172- with adapters -T10172/5- .
– Remove the propshaft.

Note

The propshaft must be kept straight when it is stored or transpor‐

ted.

Installing propshaft on Audi A8

Perform installation in reverse sequence of removal. Note the fol‐
lowing:

1. Servicing propshaft - overview 23

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Remove old, dried-out high-temperature grease from CV joints

– Bring propshaft into position and fit new bolts at rear final drive
-arrows- and at gearbox.

– Screw in securing bolts -arrows- so that centre bearing can still

be moved.

24 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Tighten bolts -1- securing propshaft on rear final drive to speci‐

fied torque ⇒ Item 5 (page 12) .
– Use counterhold tool -T10172- with adapters -T10172/5- .

– Tighten bolts securing propshaft (front end) to specified setting

⇒ Item 5 (page 12) .
– Use counterhold tool -T10172- with adapters -T10172/5- .
– Remove assembly tool -3139- .

Moving centre bearing to central position:

– Slacken securing bolts for centre bearing slightly.
– Move propshaft forward onto stop and mark position of centre
bearing on body -arrow A-.
– Move propshaft to rear onto stop and mark position of centre
bearing on body -arrow B-.
– Move propshaft to right onto stop and mark position of centre
bearing on body -arrow 1-.
– Move propshaft to left onto stop and mark position of centre
bearing on body -arrow 2-.
– Move propshaft to central position -arrow C- and -arrow 3-.
• The centre bearing must be positioned in central position be‐
tween marks -arrow A- and -arrow B- and between -arrow 1-
and -arrow 2-.
– Tighten securing bolts of centre bearing to torque
⇒ Item 8 (page 12) . 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.
Continued:
– Install heat shield below centre bearing -arrows-.

1. Servicing propshaft - overview 25

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Install heat shield -A- -arrows-.

– Install cover for rear final drive (if previously removed). Tight‐
ening torques: -arrows A- ⇒ Item 16 (page 37) and
-arrows B- ⇒ Item 13 (page 37) .
– Install exhaust system and perform stress-free alignment ⇒
Rep. Gr. 26 .

– Install both cross pieces -A- and -B- ⇒ Rep. Gr. 66 .

Tightening torques
Component Nm
Heat shield for propshaft to gearbox 25

1.3 Detaching and attaching propshaft at

rear final drive
Special tools and workshop equipment required
♦ Counterhold tool -T10172- with adapters -T10172/5-

♦ High-temperature grease -G 052 133 A2-

Detaching propshaft from rear final drive
♦ Please refer to notes ⇒ page 11 .
♦ Repairs on the propshaft should be carried out on a two pillar
hoist.

26 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Release clamps -1- and -2- and remove rear section of ex‐
haust system ⇒ Rep. Gr. 26 .

– If fitted, remove cover for rear final drive -arrows A and B-.

– Check whether there is a factory marking (coloured dot) on the

propshaft flange and on the rear final drive flange.
– If not, mark position of propshaft flange -arrow A- in relation to
rear final drive flange -arrow B- with paint marker.

– Remove bolts -1- (6x) on rear CV joint.

– Use counterhold tool -T10172- with adapters -T10172/5- .

1. Servicing propshaft - overview 27

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Separate propshaft from rear final drive and tie up -arrow-.

Attaching propshaft to rear final drive
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
♦ Remove old, dried-out high-temperature grease from CV joints
and flanges for propshaft. Put in exactly the same quantity of
fresh high-temperature grease -G 052 133 A2- .
♦ Clean remaining locking fluid out of tapped holes in flange
shaft on rear final drive. The threads can be cleaned with a
thread tap. Otherwise the securing bolts can shear off when
they are screwed in.
♦ After detaching the propshaft from the rear final drive, the ad‐
ditional balancing washer (thicker washer) that may be fitted
between the lock plate and one of the securing bolts must not
be reinstalled.
♦ Always install new securing bolts for propshaft (self-locking
bolts).

– Gasket for propshaft on rear final drive flange must be re‐

newed. Degrease sealing surface and glue on new gasket.
– Make sure that the marks on the propshaft flange -arrow A-
and on the rear final drive flange -arrow B- are in line.

– Bring propshaft into position at rear final drive and fit new bolts
-arrows-.

– Tighten bolts -1- securing propshaft on rear final drive to speci‐

fied torque ⇒ Item 5 (page 12) .
– Use counterhold tool -T10172- with adapters -T10172/5- .

28 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Install cover for rear final drive (if previously removed). Tight‐
ening torques: -arrows A- ⇒ Item 16 (page 37) and
-arrows B- ⇒ Item 13 (page 37) .
– Install rear section of exhaust system ⇒ Rep. Gr. 26 .

1. Servicing propshaft - overview 29

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

2 Measuring and marking radial run-

out at flange for propshaft
Special tools and workshop equipment required
♦ Universal dial gauge bracket -VW 387-

♦ Dial gauge
♦ Bolt M10×30

Note

♦ The radial run-out must always be measured when the flange

for the propshaft at the rear final drive has been removed. Re‐
move old paint marking and make new marking.
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
♦ If a new propshaft is being installed and the marking on the
with respect to the correctness of information in this document. Copyright by AUDI AG.

flange shaft of the rear final drive is no longer visible, the point
of maximum radial run-out (corresponding to the maximum
distance from the axis of rotation) must be measured with a
dial gauge and marked with a coloured dot -arrow B-.
♦ The coloured dot on the propshaft -arrow A- is then brought
into alignment with this marking -arrow B-.
♦ The radial run-out can be measured without removing the rear
final drive.

– Unbolt propshaft from rear final drive ⇒ page 26 .

– Secure measuring equipment to rear final drive with bolt -A-
(M10x30).
– Apply dial gauge to machined surface on inner side of flange
for propshaft -arrow- and set to “0” with a preload of 1 mm.
– Turn both rear wheels in the same direction to turn the flange
through one complete rotation.
– Mark point of maximum radial run-out with coloured dot on
outside of flange (corresponding to maximum distance from
axis of rotation).
– Then remove previous marking on flange.
– Attach propshaft ⇒ page 28 .

30 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

3 Checking gear oil in rear final drive

Special tools and workshop equipment required
♦ Drip tray -V.A.G 1306-

♦ Torque wrench -V.A.G 1331-

♦ Place drip tray -V.A.G 1306- underneath.

– Remove screw plug -arrow- to check gear oil.
The oil level is correct
Protected when the
by copyright. rear
Copying final or
for private drive is filled
commercial to the
purposes, in part or in whole, is not
bottom lip of the fillerunless
permitted [Link] 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.
• Gear oil specification ⇒ page 4 .
– Screw in plug -arrow- and tighten. Tightening torque
⇒ Item 10 (page 61)

3. Checking gear oil in rear final drive 31

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

4 Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi
A6

1 - Subframe
❑ Removing and installing
⇒ Rep. Gr. 42
2 - Hexagon bolt
3 - Hexagon bolt
❑ 40 Nm
❑ Secures final drive sup‐
port to subframe
❑ Renew nut if fitted
4 - Hexagon socket head bolts
❑ 40 Nm 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
5 - Washer with respect to the correctness of information in this document. Copyright by AUDI AG.

6 - Nut
❑ 55 Nm
❑ Self-locking
❑ Renew
7 - Rear cross member
8 - Rear final drive
❑ Removing and installing
⇒ page 32
9 - Drive shaft
❑ Removing and installing
⇒ Rep. Gr. 42
10 - Heat shield
11 - Hexagon socket head
bolts
❑ 25 Nm
12 - Final drive support
13 - Hexagon socket head bolts
❑ 40 Nm

4.1 Removing rear final drive on Audi A4,

Audi Cabriolet and Audi A6
Special tools and workshop equipment required

32 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Torque wrench -V.A.G 1332-

♦ Engine and gearbox jack -V.A.G 1383 A- with universal gear‐

box support -V.A.G 1359/2-

Removing
Refer to general repair instructions ⇒ page 8 .
– Remove rear section of exhaust system behind clamps
-arrows- ⇒ Rep. Gr. 26 .

– Check whether there is a factory marking (coloured dot) on the

propshaft flange and on the rear final drive flange.
– If not, mark position of propshaft flange -arrow A- in relation to
rear final drive flange -arrow B- with paint marker.
– Unbolt propshaft from rear final drive ⇒ page 26 .

4. Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6 33
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Separate propshaft from rear final drive and tie up to one side
-arrow-.

– Remove heat shields (left and right) from rear final drive
-arrows-.
– Unbolt drive shafts (left and right).

– Position engine and gearbox jack -V.A.G 1383 A- with univer‐

sal gearbox support -V.A.G 1359/2- under rear final drive.
– Secure rear final drive to universal gearbox support with a
strap.

– Remove securing bolts -arrows- for final drive support.

34 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Remove securing bolts -arrow A- and -arrows B- from cross

member.
Bolt -arrow A- remains in cross member.

– Slightly lower rear final drive.

– Turn rear final drive slightly to the side and pull drive shafts out
of flange shafts alternately on each side.
– Lower rear final drive completely.

Installing rear final drive on Audi A4, Audi Cabriolet and Audi A6
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Turn rear final drive to the side.
– Lift rear final drive and fit drive shafts into flange shafts alter‐
nately on each side.

– Install securing bolt -arrow A- and tighten lightly to start with.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install securing bolts -arrows B-. 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.
– Tighten securing bolts -arrow A- and -arrows B-. Tightening
torque ⇒ Item 4 (page 32)

4. Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6 35
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Tighten securing bolts -arrows- for final drive support. Tight‐

ening torque ⇒ Item 13 (page 32)

– Attach drive shafts ⇒ Rep. Gr. 42 .

– Install heat shields (left and right) on rear final drive -arrows-.
Tightening torque ⇒ Item 11 (page 32)
– Attach propshaft to rear final drive ⇒ page 28 .
– Check oil level in rear final drive ⇒ page 31 .
– Install rear section of exhaust system ⇒ Rep. Gr. 26 .

36 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

5 Exploded view - rear final drive on Audi A8

1 - Subframe
❑ Removing and installing
⇒ Rep. Gr. 42
2 - Hexagon bolt
3 - Washer
4 - Nut
❑ 40 Nm
❑ Self-locking
❑ Renew
5 - Hexagon socket head bolts
❑ 55 Nm
6 - Rear cross member
7 - Drive shaft
❑ Removing and installing
⇒ Rep. Gr. 42
8 - Heat shield
9 - Bolt with washer
❑ 25 Nm
10 - Final drive support
❑ Note assembly se‐
quence ⇒ page 41
11 - Hexagon socket head
bolts
❑ 40 Nm + 90°
❑ Renew
12 - Hexagon socket head bolt
❑ 40 Nm + 90°
❑ Renew
13 - Hexagon socket head bolts
❑ 20 Nm
14 - Washer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 - Cover 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.
❑ Depending on version
16 - Bolt with washer
❑ 40 Nm
17 - Rear final drive
❑ Removing and installing ⇒ page 38
18 - Nut
❑ Self-locking
❑ Renew
❑ Tightening torque ⇒ Rep. Gr. 42
19 - Washer
20 - Hexagon bolt

5. Exploded view - rear final drive on Audi A8 37

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

5.1 Removing and installing rear final drive

on Audi A8
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

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
♦ Engine and gearbox jack -V.A.G 1383 A- with universal sup‐
with respect to the correctness of information in this document. Copyright by AUDI AG.
port -V.A.G 1359/2-

Removing
Refer to general repair instructions ⇒ page 8 .
– Remove rear section of exhaust system behind clamps -1- and
-2- ⇒ Rep. Gr. 26 .

– If fitted, remove cover for rear final drive -arrows A and B-.

38 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Check whether there is a factory marking (coloured dot)

– Tie up propshaft to side -arrow-.

– Remove heat shields from rear final drive -arrows-.

– Unbolt drive shafts (left and right).

– Position engine and gearbox jack -V.A.G 1383 A- with univer‐

sal support -V.A.G 1359/2- below rear final drive.

5. Exploded view - rear final drive on Audi A8 39

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Unscrew bolts for final drive support -arrows A and B-.

– Remove bolts -arrows- for rear cross member.

– Slightly lower rear final drive.

– Turn rear final drive slightly to the side and pull drive shafts out
of flange shafts alternately on each side.
– Lower rear final drive completely.

Installing rear final drive on Audi A8

Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Turn final drive to the side.
– Lift rear final drive and fit drive shafts into flange shafts alter‐
nately on each side.

40 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Fit and tighten bolts -arrows-. Tightening torque

⇒ Item 5 (page 37)

Installation instructions for final drive support

– Fit bolts -A- and -B- and tighten lightly to start with (final drive
support must be in full contact with final drive).
– First tighten bolt -A-, then bolts -B-. Tightening torque
⇒ Item 11 (page 37) and ⇒ Item 12 (page 37) .

– Attach drive shafts ⇒ Rep. Gr. 42 .

– Fit heat shields on rear final drive -arrows-. Tightening torque
⇒ Item 9 (page 37)
– Renew gasket on flange for propshaft and secure propshaft to
rear final drive (markings must face each other ⇒ page 28 ).
– Check gear oil level in rear final drive ⇒ page 31 .

5. Exploded view - rear final drive on Audi A8 41

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

6 Renewing flange shaft oil seals

♦ ⇒ “6.1 Renewing flange shaft oil seals on Audi A4, Audi Cab‐
riolet”, page 42
♦ ⇒ “6.2 Renewing flange shaft oil seals on Audi A6”,
page 46
♦ ⇒ “6.3 Renewing flange shaft oil seals on Audi A8”,
page 49

6.1 Renewing flange shaft oil seals on Audi A4, Audi Cabriolet

Special tools and workshop

equipment required
♦ Punch -2062-
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Sealing grease -
G 052 128 A1- 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.

Special tools and workshop equipment required

42 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Engine and gearbox jack -V.A.G 1383 A- with universal gear‐

box support -V.A.G 1359/2-

♦ Support -T10149-

Removing
• Rear final drive installed
• Observe the general repair instructions ⇒ page 8 .

Note

All the illustrations show the left-hand side of the rear final drive.
Removal and installation of the flange shaft and oil seal on the
right-hand side is identical.

– Remove bolts -2- and detach heat shield.

– Unscrew bolts -1-.
– Push drive shaft outwards so it telescopes slightly and pivot
drive shaft out of flange shaft.

6. Renewing flange shaft oil seals 43

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

If the drive shaft cannot be pivoted clear of the flange shaft. pro‐
ceed as follows:
– Remove wheel on relevant side.
– Attach support -T10149- with one wheel bolt.
– Insert support -T10149- in engine and gearbox jack -V.A.G
1383 A- .
– Raise wheel bearing housing just far enough (not more than
10 cm) to be able to pivot drive shaft out of flange shaft.

WARNING

♦ Do not raise the wheel bearing housing further than 10 cm!

Otherwise there is a risk that the vehicle may slip off the
lifting platform.
♦ If necessary place a weight of approx. 50 kg in the luggage
compartment, or secure the vehicle to the lifting platform
using tensioning strap -T10038- or similar.
♦ Do not raise or lower vehicle while engine and gearbox
jack -V.A.G 1383 A- is positioned under the vehicle.
♦ Do not leave engine and gearbox jack -V.A.G 1383 A- un‐
der vehicle for longer than necessary.

Continued
– Remove securing bolt for flange shaft; to do this screw two
bolts into the flange and counterhold flange shaft using a lever.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Place drip tray -V.A.G 1306- underneath.
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.
– Pull out flange shaft.

– If fitted, lever out dust ring using a screwdriver.

• The dust ring will be damaged on removal and must be re‐
newed.

44 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Pry out oil seal with a suitable lever.

Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Lightly lubricate outer circumference of oil seal with gear oil.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
– Drive in new seal onto stop (take care to keep seal straight).

– Drive in new dust ring -arrow- onto stop.

– Install flange shaft.
– Screw in and tighten securing bolt for flange shaft
⇒ Item 8 (page 61) .

– Attach drive shaft ⇒ Rep. Gr. 42 .

– Install heat shield and tighten bolts -2-. Tightening torque
⇒ Item 11 (page 32)
– Check oil level in rear final drive ⇒ page 31 .
– If previously removed, install wheel and tighten wheel bolts ⇒
Wheels and tyres; Rep. Gr. 44 .

6. Renewing flange shaft oil seals 45

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

6.2 Renewing flange shaft oil seals on Audi

A6
• The oil seals can be only be renewed with the rear final drive
removed.

Special tools and workshop

equipment required
♦ Punch -2062-
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Sealing grease -
G 052 128 A1-

Special tools and workshop equipment required

♦ Engine and gearbox jack -V.A.G 1383 A- with universal gear‐
box support -V.A.G 1359/2-

46 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Removing
• Observe the general repair instructions ⇒ page 8 .
• Remove rear final drive ⇒ page 32 .

Note

All the illustrations show the left-hand side of the rear final drive.
Removal and installation of the flange shaft and oil seal on the
right-hand side is identical.

– Place drip tray -V.A.G 1306- underneath.

– Remove securing bolt for flange shaft; to do this screw two
bolts into the flange and counterhold flange shaft using a lever.
– Pull out flange shaft.

– If fitted, lever out dust ring using a screwdriver.

• The dust ring will be damaged on removal and must be re‐
newed.
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.

– Pry out oil seal with a suitable lever.

6. Renewing flange shaft oil seals 47

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– If previously fitted, drive in new dust ring -arrow- onto stop.

– Install flange shaft.

– Screw in and tighten securing bolt for flange shaft

⇒ Item 8 (page 61) .
– Install rear final drive ⇒ page 35 .
– Check oil level in rear final drive ⇒ page 31 .

48 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

6.3 Renewing flange shaft oil seals on Audi A8

Special tools and workshop

equipment required
♦ Punch -2062-
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Sealing grease -
G 052 128 A1-

Special tools and workshop equipment required

♦ Engine and gearbox jack -V.A.G 1383 A- with universal gear‐
box support -V.A.G 1359/2-

Removing
• Rear final drive installed
• Observe the general repair instructions ⇒ page 8 .

6. Renewing flange shaft oil seals 49

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Note

All the illustrations show the left-hand side of the rear final drive.
Removal and installation of the flange shaft and oil seal on the
right-hand side is identical.

– Remove rear section of exhaust system behind clamps -1- and

-2- ⇒ Rep. Gr. 26 .

– If fitted, remove cover for rear final drive -arrows A and B-.

– Remove bolts -2- and detach heat shield.

– Unscrew bolts -1- for drive shaft.

50 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Position engine and gearbox jack -V.A.G 1383 A- with univer‐

sal support -V.A.G 1359/2- below rear final drive.

– Remove bolts -arrows- for rear cross member.

– Unscrew bolts for final drive support -arrows A and B-.

– Push rear final drive towards the right as far as possible.

– Tilt rear final drive upwards -arrow A-.
– Push drive shaft outwards so it telescopes slightly -arrow B-
and pivot drive shaft out of flange shaft.

6. Renewing flange shaft oil seals 51

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Place drip tray -V.A.G 1306- underneath.

– Remove securing bolt for flange shaft; to do this screw two
bolts into the flange and counterhold flange shaft using a lever.
– Pull out flange shaft.

– If fitted, lever out dust ring using a screwdriver.

• The dust ring will be damaged on removal and must be re‐
newed.

– Pry out oil seal with a suitable lever.

52 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– If originally fitted, drive in new dust ring -arrow- onto stop.

– Install flange shaft.
– Screw in and tighten securing bolt for flange shaft
⇒ Item 8 (page 61) .

– Attach drive shaft ⇒ Rep. Gr. 42 .

– Install heat shield and tighten bolts -2-. Tightening torque
⇒ Item 11 (page 32)

– Fit and tighten bolts -arrows-. Tightening torque

⇒ Item 5 (page 37)

Installation instructions for final

Protected by copyright. drive
Copying support
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
– Fit bolts -A-with
and -B- toand
respect tighten of
the correctness lightly to start
information with (final
in this document. drive
Copyright by AUDI AG.
support must be in full contact with final drive).
– First tighten bolt -A-, then bolts -B-. Tightening torque
⇒ Item 11 (page 37) and ⇒ Item 12 (page 37) .

6. Renewing flange shaft oil seals 53

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Install cover for rear final drive (if previously removed). Tight‐
ening torques: -arrows A- ⇒ Item 16 (page 37) and
-arrows B- ⇒ Item 13 (page 37) .
– Check oil level in rear final drive ⇒ page 31 .
– Install rear section of exhaust system and perform stress-free
alignment ⇒ Rep. Gr. 26 .

54 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

7 Renewing oil seal for propshaft flange on rear final drive (rear final
drive installed)

Special tools and workshop

equipment required
♦ Drive flange installing tool -
VW 391-
♦ Multi-purpose tool -
VW 771-
♦ Puller hook -VW 771/3-
♦ Punch -3026-
♦ Counterhold tool -3028-
♦ Drift sleeve -3143-
♦ Sealing grease -
G 052 128 A1-
♦ Locking fluid -D 000 600-
♦ 2 x Hexagon bolts M 8 x 30
♦ Hexagon bolt
M 10 x 100 10.9

♦ Torque wrench -V.A.G 1332-

7. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 55
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Engine and gearbox jack -V.A.G 1383 A- with universal gear‐

box support -V.A.G 1359/2-

Removing
• Rear final drive installed
• Refer to general repair instructions ⇒ page 8 .
– Remove rear section of exhaust system ⇒ Rep. Gr. 26 .
– Detach propshaft from rear final drive and tie up ⇒ page 26 .
– Position engine and gearbox jack -V.A.G 1383 A- with univer‐
sal gearbox support -V.A.G 1359/2- under rear final drive.

– If fitted, unscrew securing bolt for final drive support

-arrow A-.
– Remove securing bolts -arrows B-.
– Carefully lower rear final drive until flange for propshaft is ac‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

cessible.
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.

56 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Determining dimension “a” and dimension “b”

♦ Distance from flange to pinion shaft = dimension “a”
♦ Distance from flange to pinion shaft securing nut = dimension
“b”
– Note measurements.

– Mark position of securing nut relative to pinion shaft with paint

-arrow-.

– Bolt on counterhold tool -3028- .

– Unscrew securing nut for pinion shaft completely. Count the
number of turns required and make a note of this number.
Re-install the originally fitted hexagon nut to secure the flange to
the pinion shaft. Otherwise it will not be possible to re-install com‐
ponents in their original position.

– Screw 2 hexagon bolts M 8 x 30 -A- into flange.

– Place drip tray -V.A.G 1306- underneath.
– Pull off flange with drive flange installing tool -VW 391- .

7. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 57
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Pull out oil seal.

Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Always renew O-ring behind flange.
– Lubricate O-ring with gear oil before installing.

– Lightly lubricate outer circumference and sealing lips of oil seal

with gear oil.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
– Drive in new seal onto stop (take care to keep seal straight).

– Drive on propshaft flange until securing nut can be fitted onto

pinion shaft.
– The threads on the pinion shaft and securing nut must be
cleaned so they are free of grease residue, and then coated
thinly with locking fluid -D 000 600- .

58 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Install the originally fitted hexagon nut and tighten to the pre‐
viously marked position -arrow- by turning the same number
of turns as noted on removal.

Checking dimension “a” and dimension “b”

♦ O-ring -1- must be installed when performing measurements.
♦ The hexagon nut must be exactly at the previously marked
position.
The measurements must be the same as noted previously
⇒ page 57 , within a tolerance of ± 0.3 mm.

– Secure hexagon nut.

Installation instructions for final drive support

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
– Fit bolts -A- and -B- and tighten lightly to start with (final drive
with respect to the correctness of information in this document. Copyright by AUDI AG.

support must be in full contact with final drive).

– First tighten bolt -A-, then bolts -B-. Tightening torque
⇒ Item 11 (page 37) and ⇒ Item 12 (page 37) .
– Install propshaft on rear final drive ⇒ page 28 .
– Check oil level in rear final drive ⇒ page 31 .
– Install rear section of exhaust system and perform stress-free
alignment ⇒ Rep. Gr. 26 .

7. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 59
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

8 General overview - dismantling and assembling rear final drive

1 - Rear final drive housing

2 - Spacer sleeve
❑ Always renew
3 - Propshaft flange
❑ Removing and installing
⇒ page 74
4 - Pinion shaft
❑ Is mated with crown
wheel, always renew to‐
gether as a set
❑ Protected
Removing andCopying
by copyright. installing
for private or commercial purposes, in part or in whole, is not
⇒ page
permitted 74authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Cover for final drive
6 - Differential
❑ Removing and installing
⇒ page 61
❑ Dismantling and assem‐
bling ⇒ page 65
7 - Crown wheel
❑ Is paired with pinion
shaft (final drive gear
set)
❑ Removing and installing
⇒ page 65

60 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

9 Exploded view - removing and installing differential

• Rear final drive removed
Refer to general repair instructions ⇒ page 8 .
Clamp rear final drive in assembly stand ⇒ page 62
1) Adjustment work is required if these components are renewed
⇒ page 87

1 - Breather sleeve
❑ With rubber valve
❑ Installation position
⇒ page 63
2 - Rear final drive housing 1)
❑ Removing and installing
pinion shaft
⇒ page 74
3 - Large tapered roller bearing
outer race1)
❑ Removing and installing
⇒ page 65
4 - Shim S1
❑ Note thickness
❑ Table of adjustments
⇒ page 87
5 - Cover for rear final drive1)
❑ With O-ring
❑ Always renew O-ring
❑ Lubricate O-ring with
gear oil before installing
6 - Torx bolt, 25 Nm
7 - Oil seal
❑ Renewing ⇒ page 42
8 - Hexagon socket head bolt,
25 Nm
9 - Flange shaft
❑ Removing and installing
⇒ page 62
10 - Screw plug, 35 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Checking gear
permitted oilauthorised
unless in rear byfinal
AUDIdrive
AG. AUDI⇒ AG
page does 31
not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Capacity and specification ⇒ page 4
11 - Differential with crown wheel 1)
❑ Dismantling and assembling ⇒ page 65
12 - Oil drain plug, 35 Nm
13 - Bush
❑ Holds magnet in position
❑ Drive in onto stop
14 - Magnet
❑ Always clean before re-installing

9. Exploded view - removing and installing differential 61

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

15 - Small tapered roller bearing outer race1)

❑ Removing and installing ⇒ page 65
16 - Shim S2
❑ Note thickness
❑ Table of adjustments ⇒ page 87
17 - Oil seal
❑ Renewing ⇒ page 42
18 - Flange shaft
❑ Removing and installing ⇒ page 62
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
19 - Hexagon socket head bolt,unless
permitted 25 Nmauthorised 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.
20 - Cover
❑ Installing ⇒ page 62

Clamping rear final drive to assembly stand

Removing and installing flange shaft

– Remove securing bolt for flange shaft; to do this screw two
bolts into the flange and counterhold flange shaft using a lever.

Driving in cover onto stop

62 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Installation position of breather sleeve

After pressing in, breather sleeve must protrude 13 mm out of
housing (dimension -a-).
Slot in rubber valve must be aligned in direction of travel.

9.1 Removing differential

Special tools and workshop

equipment required
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
port -VW 540- 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.

♦ Drip tray -V.A.G 1306-

♦ Torque wrench -
V.A.G 1331-
♦ Engine and gearbox jack -
V.A.G 1383 A- with univer‐
sal gearbox support -
V.A.G 1359/2-
♦ Sealing grease -
G 052 128 A1-

Removing
• Rear final drive removed ⇒ page 32
Clamp rear final drive in assembly stand ⇒ page 62
– Place drip tray -V.A.G 1306- underneath.
– Drain off gear oil.

9. Exploded view - removing and installing differential 63

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Remove securing bolt for flange shaft; to do this screw two

bolts into the flange and counterhold flange shaft using a lever.
– Mark flange shafts (left and right) and pull out.
– Remove bolts securing cover for rear final drive, and take off
cover.
– Pull out differential and remove.
Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Renew O-ring on cover for rear final drive; lubricate with oil
when installing.
– Fit cover for rear final drive on final drive housing and tighten
bolts in diagonal sequence ⇒ Item 6 (page 61) .
– Pack space between sealing lip and dust lip of oil seals half-
full with sealing grease -G 052 128 A1- .

– Install flange shafts and tighten ⇒ Item 8 (page 61) .

– Tighten oil drain plug on rear final drive ⇒ Item 12 (page 61) .
– Top up gear oil in rear final drive and check oil level
⇒ page 31 .

64 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

10 Exploded view - dismantling and assembling differential

Special tools and workshop

equipment required
♦ Drift -VW 295-
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 408 A-
♦ Press tool -VW 412-

10. Exploded view - dismantling and assembling differential 65

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Press tool -VW 442-

♦ Press tool -40-21-
♦ Thrust plate -40-105-
♦ Thrust piece -2050-
♦ Drift -3138-
♦ Torque wrench -
V.A.G 1332-

66 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Tapered roller bearing pull‐

er -V.A.G 1582-
♦ Adapter -V.A.G 1582/6-
♦ Puller -Kukko 44/2-

Heat tapered roller bearing inner races to 100°C before installing.

Always renew both tapered roller bearings together.
The differential must be adjusted ⇒ page 93 if the tapered roller
bearings, differential cage, rear final drive cover, final drive gear
set or the final drive housing are renewed.
Clamp rear final drive in assembly stand ⇒ page 69
2) Adjustment work is required if these components are renewed
⇒ page 87

10. Exploded view - dismantling and assembling differential 67

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

1 - Cover for rear final drive2)

2 - O-ring
❑ Always renew
❑ Lubricate with oil when
installing
3 - Rear final drive housing 2)
4 - Shim S1
❑ Note thickness
❑ Table of adjustments
⇒ page 87
5 - Small tapered roller bearing
outer race2)
❑ Driving out ⇒ page 69
❑ Pressing in
⇒ page 69
6 - Small tapered roller bearing
inner race2)
❑ Pulling off ⇒ page 70
❑ Pressing on
⇒ page 70
7 - Hexagon bolt, 60 Nm then
turn 45° further
❑ Always renew
❑ Lightly tighten bolts then
tighten in diagonal se‐
quence to correct torque
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For correct version,
permittedre‐
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
fer to ⇒ Electronic
with parts
respect to the correctness of information in this document. Copyright by AUDI AG.
catalogue
8 - Differential cage 2)
9 - Crown wheel 2)
❑ Is paired with pinion shaft (final drive gear set)
❑ Drive off with a drift ⇒ page 71
❑ Fitting on differential cage ⇒ page 72
❑ For correct version, refer to ⇒ Electronic parts catalogue
10 - Spring pin
❑ For securing differential pinion pin
❑ Drive in flush
11 - Large tapered roller bearing inner race2)
❑ Pulling off ⇒ page 70
❑ Pressing on ⇒ page 71
12 - Large tapered roller bearing outer race2)
❑ Driving out ⇒ page 71
❑ Pressing in ⇒ page 71
13 - Shim S2
❑ Note thickness
❑ Table of adjustments ⇒ page 87
14 - Threaded piece
15 - Sun wheel
❑ Installing ⇒ page 72

68 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

❑ Adjusting ⇒ page 72
16 - Planet pinion
❑ Installing ⇒ page 72
17 - Differential pinion pin
❑ Drive out with drift
18 - Shim
❑ Determining thickness ⇒ page 72
19 - Thrust washer
❑ Check for cracks

Clamping rear final drive to assembly stand

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Driving small tapered roller bearing outer race out of housing
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.

– After removing, check shims for damage.

Pressing small tapered roller bearing outer race into housing

(press onto stop)

10. Exploded view - dismantling and assembling differential 69

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Pulling off small tapered roller bearing inner race

A - Commercially available two-arm puller, e.g. puller -Kuk‐
ko 44/2-

Pressing on small tapered roller bearing inner race

WARNING

Wear protective gloves.

– Heat inner race to approx. 100°C before installing.

Pulling off large tapered roller bearing inner race

– Before setting up the puller, place thrust plate -40-105- on dif‐
ferential cage.

70 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Pressing on large tapered roller bearing inner race

WARNING

Wear protective gloves.

– Heat inner race to approx. 100°C before installing.

Driving tapered roller bearing outer race out of cover

– After removing, check shims for damage.

Pressing tapered roller bearing outer race into cover

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permittedDriving crownbywheel
unless authorised AUDI AG. offAUDI
cageAG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

10. Exploded view - dismantling and assembling differential 71

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Installing crown wheel

WARNING

Wear protective gloves.

– Heat crown wheel to approx. 100°C and install.

– When fitting crown wheel, use centralising pins -A- (shop-
made tool) to locate.

Installing differential bevel gears

– Shim thicknesses must be re-determined if sun wheels have
been renewed ⇒ page 72 .
– Install sun wheels with correct shims (as measured).
– Insert planet pinions (spaced 180° apart) and pivot into posi‐
tion -arrow-.
– Fit and align thrust washers.
– Insert threaded pieces, ensuring they are seated correctly.
– Drive differentialProtected
pinionbypin into final position and secure.
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.

Adjusting differential bevel gears

– Insert sun wheels with 0.5 mm thick shims.
– Insert planet pinions with thrust washers (spaced at 180°).
Ensure that the thrust washers are not interchanged from this
point onwards.
– Drive in differential pinion pin.
– Press planet pinions outwards.
– Press sun wheels in direction of -arrows- and check the
amount of play.
– Determine the thickest shim that can still just be fitted for the
sun wheels on each side.
– Select shims of equal thickness.
Table of shims
Shim thickness (mm)
0.50 0.70 0.90
0.60 0.80 1.00
Select correct shims from ⇒ Electronic parts catalogue .

72 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

If there is no measurable play and the bevel gears can just still be
turned, the adjustment is acceptable.

10. Exploded view - dismantling and assembling differential 73

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

11 Exploded view - removing and installing pinion shaft; dismantling and

assembling pinion shaft
Always renew both tapered roller bearings together.
Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
Clamp rear final drive in assembly stand ⇒ page 79
3) Adjustment work is required if these components are renewed
⇒ page 87

1 - Nut
❑ Removing ⇒ page 80
❑ Installing ⇒ page 83
❑ Measuring friction tor‐
que ⇒ page 83
❑ Securing ⇒ page 84
2 - Flange for propshaft
❑ Pulling off ⇒ page 80
❑ Installing ⇒ page 83
3 - Oil seal
❑ Pulling out ⇒ page 80
❑ Driving in ⇒ page 83
4 - O-ring
❑ Always renew
❑ Lubricate with gear oil
when installing
⇒ page 82
5 - Small tapered roller bearing
inner race3)
❑ Pressing out pinion
shaft ⇒ page 80
❑ Installing ⇒ page 82 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
6 - Small tapered roller bearing with respect to the correctness of information in this document. Copyright by AUDI AG.

outer race3)
❑ Pulling out ⇒ page 81
❑ Pressing in
⇒ page 82
7 - Spacer sleeve3)
❑ Always renew
8 - Rear final drive housing 3)
9 - Shim S3
❑ Note thickness
❑ Table of adjustments ⇒ page 87
10 - Large tapered roller bearing outer race3)
❑ Driving out ⇒ page 81
❑ Drawing in ⇒ page 82
11 - Large tapered roller bearing inner race3)
❑ Pressing off ⇒ page 81
❑ Pressing on ⇒ page 81

74 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

12 - Pinion shaft3)
❑ Paired with crown wheel
❑ Renew together if necessary

11.1 Removing and installing pinion shaft; dismantling and assembling pinion
shaft

Special tools and workshop

equipment required
♦ Drive flange installing tool -
VW 391-
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 408 A-
♦ Press tool -VW 412-

11. Exploded view - removing and installing pinion shaft; dismantling and assembling pinion shaft 75
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Support rails -VW 457-

♦ Removing tool -VW 460-
♦ Assembly ring -VW 470/1-
♦ Tube -VW 519-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Thrust plate -30-205-

76 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Installing ring -2003/3-

♦ Thrust plate -3005-
♦ Counterhold tool -3028-
♦ Thrust pad -3062-
♦ Drift -3138-
♦ Drift sleeve -3143-

11. Exploded view - removing and installing pinion shaft; dismantling and assembling pinion shaft 77
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Multi-purpose tool -
VW 771-
♦ Punch -3026-
♦ Assembly tool -3253-
♦ Engine and gearbox jack -
V.A.G 1383 A- with univer‐
sal gearbox support -
V.A.G 1359/2-

78 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

♦ Drift -VW 295-

♦ Friction gauge -VAS 6222-
♦ Splitter -Kukko 17/2-
♦ Internal puller -Kukko 21/7-
♦ Counter-support -Kuk‐
ko 22/2-
♦ Sealing grease -
G 052 128 A1-
♦ Socket (long) -SW 36-
♦ 2 x Hexagon bolts M 8 x 30

Clamping rear final drive to assembly stand

11. Exploded view - removing and installing pinion shaft; dismantling and assembling pinion shaft 79
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Removing nut for pinion shaft

A - Screw in 2 hexagon bolts M 8 x 30 .
B - Socket (long), 36 mm
– When loosening nut, rear final drive must be supported with
engine and gearbox jack -V.A.G 1383 A- and universal gear‐
box support -V.A.G 1359/2- .

Pulling off flange

A - Screw 2 hexagon bolts M 8 x 30 into flange.

Pulling out oil seal for propshaft flange

Pressing pinion shaft out of tapered roller bearing inner race

80 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Pulling out small tapered roller bearing outer race

A - counter-support -Kukko 22/2-
B - internal puller 46 … 56 mm , e.g. -Kukko 21/7-

Driving out large tapered roller bearing outer race

– After removing, check shims for damage.

Pressing off large tapered roller bearing inner race

A - splitter 22 … 115 mm , e.g. -Kukko 17/2-

Pressing on large tapered roller bearing inner race

WARNING

Wear protective gloves.

– Heat inner race to approx. 100°C before installing.

11. Exploded view - removing and installing pinion shaft; dismantling and assembling pinion shaft 81
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Pulling in large tapered roller bearing outer race

– Lightly oil bearing seat in rear final drive housing.
– Fit previously determined shim ”S3” for pinion shaft.
Lettering “oben” (top) on thrust plate -3253/4- faces nut of puller.

Pressing in small tapered roller bearing outer race

– Lightly oil bearing seat in rear final drive housing.
– Use drift -VW 295- and thrust plate -30-205- for pressing in
outer race.

Installing small tapered roller bearing inner race

– Insert pinion shaft with new spacer sleeve.

WARNING

Wear protective gloves.

– Heat inner race to about 100°C.

– Press pinion shaft up and press inner race fully home onto stop
with press tool -40-21- .

Installing O-ring
– Lubricate O-ring with gear oil when installing.

82 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Driving in oil seal for propshaft flange

– Lightly lubricate outer circumference of oil seal with gear oil.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
– Drive in new seal onto stop in rear final drive housing (take
care to keep seal straight).

Installing flange
– Drive propshaft flange onto pinion shaft until the securing nut
can be fitted.

Tightening nut for pinion shaft and setting friction torque

B - Socket (long), 36 mm
– When tightening nut, rear final drive must be supported with
engine and gearbox jack -V.A.G 1383 A- and universal gear‐
box support -V.A.G 1359/2- .
Only increase tightening torque slowly. Stop and and check fric‐
tion torque several times. If the specified friction torque is excee‐
ded, the spacer sleeve must be renewed and the adjustment
procedure repeated. A spacer sleeve which has been com‐
pressed too much cannot be re-used.

Measuring friction torque

Use bearing preload gauge -VAS 6222- and socket (long) -
SW 36- for measuring friction torque.
Set friction torque as follows:
New bearings Used bearings4)
150 … 200 Ncm 30 … 60 Ncm
4) run at least 50 km (30 miles)

11. Exploded view - removing and installing pinion shaft; dismantling and assembling pinion shaft 83
Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Securing nut for pinion shaft

– Secure nut for pinion shaft.
– Measure radial run-out at flange for propshaft ⇒ page 30 .

84 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

12 Adjusting pinion shaft and crown

wheel

Note

♦ Careful adjustment of the crown wheel and pinion shaft is es‐

sential to ensure that the final drive gives long service and runs
silently. During manufacture the crown wheel and pinion shaft
are matched and checked on testing machines to ensure cor‐
rect mesh pattern and silent running. The position for quietest
running is obtained by moving the pinion shaft axially, while at
the same time maintaining the backlash within the specified
tolerance.
♦ The deviation, or tolerance “r”, which is related to the master
gauge “Ro”, is marked on the outer circumference of the crown
wheel.
♦ Only renew gear set (crown wheel and pinion shaft) together!

12.1 Adjustment and marking of final drive gear set

1 - Identification “O937” de‐

notes an Oerlikon gear set with
a ratio of 37 : 9.
The gear set may also be man‐
ufactured by Klingelnberg
“K937” or Gleasen “G937”.

2 - -312- number of matched

pair of gears
3 - Allowance “r” is based on
the master gauge used on the
test machine in production.
The allowance “r” is always
given in 1/100 mm. For exam‐
ple: “25” indicates r = 0.25 mm

12. Adjusting pinion shaft and crown wheel 85

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Ro - Length of master gauge

used on test machine “Ro”.
Ro - Crown wheel = 57.50 mm
R - Actual distance between
centre axis of crown wheel and
face of pinion shaft at point
with quietest running for this
gear set.
Vo - Hypoid offset
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.

86 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

12.2 Position of shims

S1 - Shim for crown wheel in

cover for final drive
S2 - Shim for crown wheel in
rear final drive housing
S3 - Shim for pinion shaft in
rear final drive housing

12.3 Table of adjustments

♦ If repairs have been carried out on the rear final drive it is only
necessary to re-adjust the pinion shaft or the complete gear
set if components have been renewed which have a direct ef‐
fect on the adjustment of the final drive. Refer to the following
table to avoid unnecessary adjustment work:
Components requiring Crown wheel Pinion shaft Backlash
adjustment:
(S1 + S2) S3 0.12 - 0.22 mm
via allowance “r”
⇒ page 93 ⇒ page 88 ⇒ page 97
Component renewed

12. Adjusting pinion shaft and crown wheel 87

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Rear final drive housing X X X

Differential cage X X
Tapered roller bearings X X
for pinion shaft
Tapered roller bearings X X
for differential
Final drive gear set X X X
Cover for rear final drive X X

12.4 Recommended sequence for adjusting

gear set
The following work sequence is recommended to save time when
the crown wheel and pinion shaft have to be adjusted:
♦ Determine total shim thickness “Stotal” (S1 plus S2) to obtain
specified preload on differential tapered roller bearings.
♦ Determine shim thickness “S3” required for specified position
of pinion shaft.
♦ Distribute total shim thickness “Stotal” (S1 plus S2) so that the
specified backlash between crown wheel and pinion shaft is
achieved.
The object of the adjustment is to reproduce the setting for qui‐
etest possible running, as obtained on the test machine in pro‐
duction. For good results, maximum care and cleanliness are very
important when performing repairs and taking measurements.

12.5 Adjusting pinion shaft

The pinion shaft only needs to be re-adjusted according to the
following instructions if the final drive gear set, the tapered roller
bearings for the pinion shaft or the rear final drive housing are
being renewed ⇒ page 87 .

88 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Special tools and workshop

equipment required
♦ Universal measuring tool -
VW 385-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Bearing preload gauge -
VAS 6222-
♦ Dial gauge
♦ Socket (long) -SW 36-

Determining thickness of shim "S3"

• Before adjusting pinion shaft, first determine total shim thick‐
ness “Stotal” (S1 plus S2) requiredProtected
for specified preload
by copyright. onprivate or commercial purposes, in part or in whole, is not
Copying for
differential tapered roller bearings ⇒ page 93 .
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.
(Setting preload of tapered roller bearing for pinion shaft)
– Clamp rear final drive in assembly stand ⇒ page 79
– Fit both tapered roller bearing outer races without shims into
housing ⇒ page 82 .
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Only install spacer sleeve for final friction torque measurement
(after determining shim “S3”).
– Fit pinion shaft in housing with large tapered roller bearing in‐
ner race but without spacer sleeve.

12. Adjusting pinion shaft and crown wheel 89

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Heat small tapered roller bearing inner race to approx. 100°C

and fit on pinion shaft.

WARNING

Wear protective gloves.

– Fit propshaft flange and tighten hexagon nut for flange

⇒ page 83 .

Only increase tightening torque slowly. Stop and and check fric‐
tion torque several times ⇒ page 90 .
Use bearing preload gauge -VAS 6222- and socket (long) -
SW 36- for measuring friction torque.
Set friction torque as follows:
New bearings Used bearings5)
150 … 200 Ncm 30 … 60 Ncm
5) run at least 50 km (30 miles)

Determining dimension “e”

– Adjust setting ring of universal measuring tool -VW 385/1- to
dimension “a” = 60 mm.
– Set the adjustable ring to dimension “b” = 55 mm.

– Assemble universal mandrel -VW 385/1- as shown.

♦ Dial gauge extension -VW 385/15- = 9 mm long
♦ Set universal master gauge -VW 385/30- to R0 = 57.50 mm.
♦ Set dial gauge (3 mm measuring range) to zero with 2 mm
preload.
– Turn pinion shaft at least 8 turns in both directions to settle the
tapered roller bearings.

90 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Place end measuring plate on face of pinion shaft.

– Remove master gauge and insert measuring tool into housing.

– Fit cover for rear final drive and tighten 4 bolts.
– Using the adjustable ring, move the 2nd centring disc out‐
wards as far as possible so that the measuring tool can still
just be turned by hand.

12. Adjusting pinion shaft and crown wheel 91

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Turn measuring tool until dial gauge extension contacts end

measuring plate and gauge indicates maximum deflection (re‐
turn point). The measured value is dimension “e” (in red scale).
♦ Example: dimension “e” = 1.60 mm
Determining thickness of shim “S3”
“S3” = e – r

e - Measured value (maximum deflection)

r - Allowance (marked on crown wheel in 1/100 mm)
Example:
Dial gauge reading “e” 1.60 mm
Allowance “r” marked on crown wheel – 0.42 mm
Shim thickness “S3” = 1.18 mm

– Determine shim(s) as accurately as possible according to ta‐

ble. For Part Nos. refer to ⇒ Electronic parts catalogue .
The following shims are available for “S3”
Shim thickness (mm)
0.95 1.20 1.45
1.00 1.25 1.50
1.05 1.30 1.55
1.10 1.35
1.15 1.40
– Remove universal mandrel. 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
– Remove pinion shaft and outer race of large tapered
with respect to the roller
correctness of information in this document. Copyright by AUDI AG.
bearing and re-install together with calculated shims “S3” and
new spacer sleeve ⇒ page 74 .
– Fit inner race of small tapered roller bearing and tighten nut
for pinion shaft until specified friction torque is obtained
⇒ page 83 .

Only increase tightening torque slowly. Stop and and check fric‐
tion torque several times ⇒ page 92 .

Caution

If the specified friction torque is exceeded, the spacer sleeve

must be renewed and the adjustment procedure repeated.
A spacer sleeve which has been compressed too much cannot
be re-used.

Set friction torque as follows:

New bearings Used bearings6)
150 … 200 Ncm 30 … 60 Ncm
6) run at least 50 km (30 miles)

92 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Checking dimension “r”

– Turn pinion shaft at least 8 turns in both directions to settle the
tapered roller bearings.
Insert universal mandrel -VW 385/1- and measure dimension “r”.
If the correct shims have been selected, the dial gauge (reading
anti-clockwise in the red range), should now show the allowance
“r” within a tolerance of + 0.05 mm

– Secure hexagon nut.

– After securing the nut for the pinion shaft, measure the radial
run-out at the flange for the propshaft, and mark accordingly
⇒ page 30 .

12.6 Adjusting crown wheel

(Adjusting differential)

Note

Re-adjustment of the crown wheel is required if the rear final drive

housing, final drive cover, differential tapered roller bearings, dif‐
ferential cage or final drive gear set have been renewed.

Table of adjustments ⇒ page 87

12. Adjusting pinion shaft and crown wheel 93

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Special tools and workshop

equipment required
♦ End measuring plate -
VW 385/17-
♦ Universal dial gauge brack‐
et -VW 387-
♦ Measuring lever -VW 388-
♦ Crown wheel adjusting tool
-VW 521-
♦ Torque wrench -
V.A.G 1331-
♦ Dial gauge
♦ Hexagon bolt M 8 x 45

Determining total shim thickness “Stotal” for shims “S1” plus

“S2”
(Setting preload of tapered roller bearings for differential)
• Pinion shaft is removed.
• If only the tapered roller bearings for the differential are being
renewed, the crown wheel can be removed from the differen‐
tial cage. The pinion shaft then does not have to be removed.
• Shims available for “S1” + “S2”: refer to ⇒ Electronic parts
catalogue .
– Protected
Pry outby flange
[Link]
Copyingoil seal using
for private assembly
or commercial purposes,lever.
in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove
with respecttapered rollerofbearing
to the correctness information outer races for
in this document. differential
Copyright and
by AUDI AG.
take out shims ⇒ page 65 .
– Press outer race of tapered roller bearing together with a
1.00 mm thick shim onto stop in housing (S2 side)
⇒ page 65 .

94 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Note

For measurement purposes a 1.0 mm thick shim “S2” is inserted

provisionally. This is referred to in the following as “S2*”. “S2*” is
exchanged with the final shim “S2” after determining backlash.

– Press outer race for tapered roller bearing without shim “S1”
into cover for final drive.
– Fit differential in housing.
Crown wheel is on same side as cover.
– Fit cover for final drive and tighten 4 bolts to 25 Nm in diagonal
sequence.
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.

– Attach special tools to differential cage on final drive housing

side.
– Turn final drive unit so that cover side faces upwards.
– Turn differential 8 turns in both directions to settle tapered roll‐
er bearings.

– Attach measuring equipment.

– Place measuring plate -VW 385/17- on differential.
A - Dial gauge extension -30 mm-
– Screw in hexagon bolt M 8 x 45 -B-.
– Apply dial gauge extension to centre of measuring plate -
VW 385/17- .
– Set dial gauge (3 mm measuring range) to “0” with 2 mm pre‐
load.

12. Adjusting pinion shaft and crown wheel 95

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

– Raise differential in direction of -arrow- without turning, read

play off dial gauge and note down (example: 0.50 mm).
If the measurement has to be repeated, the differential must again
first be turned 8 turns in each direction to settle the tapered roller
bearings.
Formula: “Stotal” = “S2*” + measured value + bearing preload
Example:
Example:
Inserted shim “S2*” 1.00 mm
+ Measured value 0.50 mm
+ Bearing preload (constant value) 0.30 mm
= Total shim thickness “Stotal” for “S1” plus “S2” 1.80 mm

Determining thickness of shim “S1*”

Note
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
♦ Provisional shim “S1*” is replaced with final shim “S1” after
with respect to the correctness of information in this document. Copyright by AUDI AG.

determining backlash.
♦ Total shim thickness "Stotal" remains unchanged.

Formula: “S1” = “Stotal” – “S2”

Example:
Total shim thickness “Stotal” for “S1” + “S2” 1.80 mm
– Inserted shim(s) “S2*” 1.00 mm
= Thickness of shim “S1*” 0.80 mm
• Select correct shim(s) from ⇒ Electronic parts catalogue .

96 Rep. Gr.39 - Final drive - rear differential

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

Measuring backlash
(Position of crown wheel in final drive housing)
• Pinion shaft installed with shim S3
• Outer races for tapered roller bearings installed in final drive
housing with shims S1* + S2*
• Differential installed
– Fit cover for final drive and tighten bolts to 25 Nm.
– Turn differential 5 turns in both directions to settle tapered roll‐
er bearings.
– Attach measuring equipment.
– Fit dial gauge with dial gauge extension -VW 382/10- (6 mm
flat).
Set measuring lever -VW 388- to dimension “a” = 60 mm.
Measure play between teeth faces (backlash) as follows:
– Turn crown wheel until it makes contact with the face of one
tooth (end of backlash travel).
– Preload dial gauge to 2 mm and set to “0”.
– Turn back crown wheel until it makes contact with opposite
tooth face (backlash).
– Take backlash reading and note down measured value.
– Turn crown wheel through 90° and repeat measurements an‐
other 3 times.
Determining average backlash
– Add the four measured values together and divide by four.
Example:
1st measured value 0.28 mm
+ 2nd measured value 0.30 mm
+ 3rd measured value 0.30 mm
+ 4th measured value 0.28 mm
= Sum of measured values 1.16 mm
• Result: the average backlash is 1.16 mm : 4 = 0.29 mm

Note

If the individual measurements differ by more than 0.06 mm, this

means that the installation of the crown wheel is not correct or
that the final drive gear set itself is defective. Check installation;
renew final drive gear set if necessary.

Determining thickness of shim “S2”by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Formula: “S2” = “S2*” – backlash + toliftthe correctness of information in this document. Copyright by AUDI AG.
with respect

Example:
Inserted shim(s) “S2*” 1.00 mm
– Average backlash 0.29 mm
+ Lift (desired average value for backlash) 0.15 mm
= Thickness of shim “S2” 0.86 mm

12. Adjusting pinion shaft and crown wheel 97

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 01R - Edition 02.2010

• For available shim(s) refer to ⇒ Electronic parts catalogue .

• The exact shim thickness required can be obtained by using
the shim tolerance variations. Install two shims if necessary.
Determining thickness of shim “S1”
Formula: “S1” = “Stotal” – “S2”

Example:
Total shim thickness “Stotal” 1.80 mm
for “S1” plus “S2”
– Thickness of shim “S2” 0.86 mm
= Thickness of shim “S1” 0.94 mm

• For available shim(s) refer to ⇒ Electronic parts catalogue .

• The exact shim thickness required can be obtained by using
the shim tolerance variations. Install two shims if necessary.
– Install correct shims: S1 on crown wheel side, and S2 opposite
crown wheel. If necessary use 2 shims.

Checking adjustment
– After installing shims “S1” and “S2”, turn differential 5 turns in
both directions so that the tapered roller bearings settle.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Measure backlash four times on circumference. 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.
• Specification: 0.12 ... 0.22 mm.

Note

♦ Adjustment must be repeated if backlash is outside tolerance.

The total shim thickness “Stotal” must remain unchanged.
♦ The discrepancy between individual measured values must
not exceed 0.06 mm.

98 Rep. Gr.39 - Final drive - rear differential

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