A4 Rear Differential Rear Final Drive

2005 Audi A4 Quattro
REAR DIFFERENTIAL Rear Final Drive
00 GENERAL, TECHNICAL DATA

REAR FINAL DRIVE IDENTIFICATION
The 01R rear final drive in the Audi A4 2001 > is assigned to the following transmissions:
 5-Speed Manual Transmission 01A, AWD

 6-speed Manual Transmission 01E, AWD
 6-speed Manual Transmission 02X, AWD
 6-speed Manual Transmission 0A3, AWD
 Automatic Transmission 01V, AWD

 Automatic Transmission 09L, AWD
Allocation. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD, Technical
cardiagn.com
data
Fig. 1: Locations Of Final Drive Identification

Courtesy of VOLKSWAGEN UNITED STATES, INC.
Location on final drive
Code letters and date of manufacture (arrow 1)
Final drive 01R (arrow 2)
1:12:02 AM
1:12:05 Page 1
Fig. 2: Final Drive 01R

Final drive 01R (arrow 2)
cardiagn.com
Fig. 3: Locating Code Letters And Date Of Manufacture Of Final Drive
Code letters and manufacturing data for the final drive
Example: EUB 26 04 00
I I I I
I I I I
Code letters Day Month Year (2000)
of manufacture
Additional data is production-related
CODE LETTERS, TRANSMISSION RATIOS, CAPACITIES
Allocation of mechanical units: 5-speed Manual Transmission 01A AWD
Rear final drive 01R
1:12:02 AM Page 2
Code letters ETT ETS

Production from 02.01 09.00
to - -
Allocation Model Audi A4 2002 > Audi A4 2002 >
Engine 1.8 l -110 kW 1.8 l -125 kW
1.8 l -120 kW 2.0 l -132 kW
3.0 l -162 kW
Ratio Final drive Z2:Z1 = i 35 : 9 = 3.889 35 : 9 = 3.889
Capacity 1.5 ltr.
Specification Gear oil G 052 145 A1 (container size, 0.5 liter)
Gear oil G 052 145 S2 (container size, 1.0 liter)
Axle shaft flange diameter 70.7 mm 75.5 mm
Allocation of mechanical units: 6-speed Manual Transmission 01E, AWD
cardiagn.com
Code letters ETQ FUB
to - -
Engine 3.0 l - 162 kW 1.8 l - 140 kW
3.0 l - 162 kW
Capacity 1.5 ltr.
Allocation of mechanical units: 6-speed Manual Transmission 02X, AWD

Code ETQ ETR ETS
Production from 09.00 06.03 09.00
to - - -
Allocation Model Audi A4 2002 > Audi A4 2002 > Audi A4 2002 >
Engine 1.8 l - 125 kW 1.8 l - 120 kW 3.0 l - 162 kW
Ratio Final drive Z2 : Z1 = i 37 : 9 = 4.111 37 : 9 = 4.111 35 : 9 = 3.889
Capacity 1.5 ltr.
Axle shaft flange diameter 75.5 mm 70.7 mm 75.5 mm
1:12:02 AM Page 3
Allocation of mechanical units: 6-speed Manual Transmission 0A3, AWD

Code EXZ
Production from 11.02
to -
Allocation Model Audi A4 2002 >
Engine 4.2 l - 253 kW
Ratio Final drive Z2 : Z1 = i 35 : 9 = 3.889
Capacity 1.5 ltr.
Specification Axle oil G 052 145 A1 (container
size, 0.5 liter)
Axle oil G 052 145 S2 (container
size, 1.0 liter)
Axle shaft flange diameter 75.5 mm
cardiagn.com
Allocation of mechanical units: Automatic Transmission 01V FWD and AWD

Code letters ETQ ETS
to - -
Engine 1.8 l - 125 kW 3.0 l - 162 kW
2.0 l - 132 kW
3.0 l - 162 kW
Capacity 1.5 ltr.
Allocation of mechanical units: Automatic Gearbox 09L, AWD

Code GDF
Production from 07.03
to -
Allocation Model Audi A4 2002 >
Engine 4.2 L - 253 kW
Ratio Final drive Z2 : Z1 = i 31 : 10 = 3.100
Capacity 1.5 ltr.
1:12:02 AM Page 4
Specification Axle oil G 052 145 A1 (container

size, 0.5 liter)
Axle oil G 052 145 S2 (container
size, 1.0 liter)
Axle shaft flange diameter 75.5 mm
TRANSMISSION LAYOUT
Transmission layout
cardiagn.com
Fig. 4: Transmission, Overview
 Illustrated with the 6-speed manual transmission 01E all wheel drive
Designation
1:12:03 AM Page 5
1 - Engine
2 - Clutch
3 - Manual transmission
4 - Input shaft
5 - Front differential
6 - Front drive pinion (output shaft)
7 - Hollow shaft
8 - Torsen differential
cardiagn.com
9 - Drive shaft
10 - Rear drive pinion
11 - Rear differential
Arrows in direction of travel
1:12:03 AM Page 6
cardiagn.com
Fig. 5: Transmission, Overview
Ratio
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A1 - Front final drive
A2 - Rear final drive
T - Speedometer drive
1:12:03 AM Page 7
Arrows in direction of travel
REPAIR INSTRUCTIONS
Repair instructions
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful
transmission repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned
at various points in the article, are summarized here. They apply to this article.
Transmission
 When replacing rear final drive the oil level in rear final drive must be checked and, if necessary,
corrected. Refer to Gear oil level in rear final drive, checking.
cardiagn.com
 Capacities and specifications. Refer to Allocation of mechanical units: 5-speed Manual Transmission
01A AWD.
 When assembling mounting brackets as well as waxed components clean contact surfaces. The contact
surfaces must be free of wax and grease.
Gaskets, sealing rings
 Replace O-rings.
 Radial shaft oil seals.
Before installing:
Fig. 6: Identifying Space Between Oil Seal Sealing Lips

Lightly oil outer circumference and pack space between sealing lips -arrow- half-full with sealing grease G 052
128 A1.
After installation:
1:12:03 AM Page 8
Check gear oil in rear final drive; if necessary top off to lower edge of oil filler hole, specification. Refer to
Allocation of mechanical units: 5-speed Manual Transmission 01A AWD.
Locking elements
 Replace circlips.
 Do not over-stretch circlips.
 Circlips must be properly seated in the base of the groove.
cardiagn.com
Fig. 7: Identifying Spring Pins Installation Position
 Replace spring pins.
Installation position: Slot longitudinal to line of force.
Nuts, bolts
 Nuts and bolts which secure covers and housings should be loosened and tightened diagonally.
 Parts which are particularly sensitive must not be tilted; loosen or tighten diagonally in stages.
 Tightening torques stated apply to non-oiled nuts and bolts.
 Replace self-locking bolts and nuts.
 Make sure with all screw connections that contact surfaces as well as bolts and nuts are only waxed after
assembly, if necessary.
Bearings
 Attach needle bearing with the written side (greater plate thickness) to the installing tool.
 Install new taper roller bearings in delivery condition and do not oil.
 Always replace taper roller bearings on one shaft together and use new bearings from a single
manufacturer.
 Heat inner races to approx. 100°C before installing.
1:12:03 AM Page 9
 Do not interchange outer or inner races of bearings of the same size. The bearings are paired.
Adjustment shims
 Check thickness of shims by measuring at several points with a micrometer. Different tolerances make it
possible to obtain exact shim thickness required.
 Check for burrs and damage.
 Install only adjustment shims which are in perfect condition.
; Removing and installing exhaust-system components ; Removing and installing exhaust-system components ;
Removing and installing exhaust-system components ; Removing and installing exhaust-system components ;
Removing and installing exhaust-system components ; Removing and installing exhaust-system components
cardiagn.com
1:12:03 AM Page 10
REAR DIFFERENTIAL Rear Final Drive 0AR
REAR DIFFERENTIAL
Rear Final Drive 0AR
00 - GENERAL, TECHNICAL DATA

IDENTIFICATION OF REAR FINAL DRIVE
Identification of rear final drive
Rear Final Drive 0AR is allocated to the following transmissions:
 6-speed Manual Transmission 02X

 6 speed Manual Transmission 0A3
 Automatic Transmission 09E All Wheel Drive (AWD)
cardiagn.com
 Automatic Transmission 09L All Wheel Drive (AWD)
Allocation, Audi A4 2002 >, Cabriolet 2003 > --> Code letters, aggregate allocation, ratios, capacities, Audi
A4 2002 >, Cabriolet 2003 >
Allocation, Audi A6 2005 > --> Code letters, aggregate allocation, ratios, capacities, Audi A6 2005 >
Allocation, Audi A8 2003 > --> Code letters, aggregate allocation, ratios, capacities, Audi A8 2004 >
Allocation at rear final drive
Fig. 1: Locating Final Drive 0AR & Identification/Date Of Construction

Final Drive 0AR - arrow 1 -
Identification and date of construction - arrow 2 -
1:13:05 AM
1:13:12 Page 1
Fig. 2: Identifying Final Drive 0AR & Identification And Date Of Construction
Final Drive 0AR - arrow -
cardiagn.com
Fig. 3: Identifying Code Letters And Date Of Manufacture Of Rear Final Drive
Code letters and date of manufacture of rear final drive
Example: HNR 14 04 05
L L L L
Code letters Day Month Year - 2005 - of
manufacturing
Further data can be ignored.
NOTE:  If rear final drive is replaced, not only the final drive code but also the PR
number and the vehicle engine code must always be noted . Only in this
way is a correct allocation guaranteed.
Code letters, aggregate allocation, ratios, capacities, Audi A4 2002 >, Cabriolet 2003 >
1:13:05 AM Page 2
Rear final drive 0AR

Code letters HNL HNP HNR
Manufactured from to 06.05 11.05 06.05
Allocation Engine 4.2 L - 253 kW 4.2 L - 253 kW 4.2 L - 309 kW
S4 3.2 L - 188 RS4
kW FSI 2.0 L -
147 kW TFSI
Ratio Final drive Z 2 : 31 : 10 = 3.100 35 : 9 = 3.889 37 : 9 = 4.111
Z1
Drive axle flange dia. 75.5 mm 75.5 mm 75.5 mm
Capacity 0.9 liter
Specification Axle oil G 052 145 A1 (container size 0.5 Liter)
Axle oil G 052 145 S2 (container size 1.0 Liter)
Allocation to engine, manual transmission and automatic transmission via
cardiagn.com
Code letters HNQ HUN HUP
Allocation Engine 1.8 L -120 kW 3.2 L -188 kW 3.2 L -188 kW
FSI FSI
Z1
Drive axle flange dia. 70.7 mm 75.5 mm 75.5 mm
Capacity 0.9 liter

Code letters HUQ
Manufactured from to 11.05
Allocation Engine 3.0 L -160 kW
2.0 L -147 kW
TFSI
Ratio Final drive Z 2 : 35 : 9 = 3,889
Z1
Drive axle flange dia. 75.5 mm
Capacity 0.9 liter
1:13:05 AM Page 3
Code letters, aggregate allocation, ratios, capacities, Audi A6 2005 >

Code letters HNL HNN HUN
Allocation Engine 3.2 L -188 kW 4.2 L - 246 kW 3.2 L - 188 kW
FSI 4.2 L - 254 kW FSI
Z1
Drive axle flange 75.5 mm 75.5 mm 75.5 mm
Capacity 0.9 liter
cardiagn.com
Code letters, aggregate allocation, ratios, capacities, Audi A8 2004 >

Code letters HNK HNM
Manufactured from to 06.05 06.05
Allocation Engine 4.2 L - 213 kW 6.0 L - 331 kW
4.2 L - 246 kW
Ratio Final drive Z 2 : 31 : 10 = 3.100 32 : 9 = 3.555
Z1
Drive axle flange dia. 108 mm 108 mm
Capacity 0.9 liter
POWER TRANSFER, OVERVIEW
Power transfer, overview
 Depicted with 6 speed manual transmission 0A3 All Wheel Drive.
Nomenclature
NOTE:  Arrows in direction of travel
1:13:05 AM Page 4
cardiagn.com
Fig. 4: Power Transfer, Overview
1 - Engine
2 - Clutch
3 - Manual transmission
4 - Input shaft (main shaft)
5 - Front differential
6 - Front pinion shaft (output shaft)
7 - Hollow shaft
1:13:05 AM Page 5
8 - Torsen differential
9 - Driveshaft
10 - Rear drive pinion
11 - Rear differential
Ratio
NOTE:  Arrows in direction of travel
I - 1st Gear
II - 2nd Gear
cardiagn.com
III - 3rd Gear
IV - 4th Gear
V - 5th Gear
VI - 6th Gear
R - Reverse Gear
A1 - Final drive-front
A2 - Rear final drive
GENERAL REPAIR NOTES
General Repair Notes
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful
transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned
at various points in the article are summarized under the term "components" --> Components. They apply to
this article.
Vehicle jack mode on vehicles with air spring suspension
Before raising a vehicle with air spring suspension on a 2-pillar lifting platform (wheels off the ground), first
activate the vehicle jack mode --> 43 - SELF-LEVELING SUSPENSION .
1:13:05 AM Page 6
Components
Rear Final Drive
 Allocate bolts and other components according to the Final Drive code via .
 When replacing rear final drive, check and if necessary, correct oil level in final drive --> Axle oil in rear
final drive, checking.
 Capacities and specification - Audi A4 2002 >, Cabriolet 2003 > --> Code letters, aggregate allocation,
ratios, capacities, Audi A4 2002 >, Cabriolet 2003 > , Audi A6 2005 > --> Code letters, aggregate
allocation, ratios, capacities, Audi A6 2005 > , Audi A8 2004 > --> Code letters, aggregate allocation,
ratios, capacities, Audi A8 2004 >
 Clean contact surfaces when repairing mounting brackets and waxed components. Contact surfaces must
be completely free of oil and grease.
 Thoroughly clean all connections and surrounding area before disconnecting.
cardiagn.com
O-rings, gaskets, seals
 Always replace O-rings, gaskets and seals.

 After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs
resulting from removal, or for other signs of damage.
 Thoroughly clean housing joint surfaces before assembling.
Fig. 5: Identifying Space Between Oil Seal Sealing Lips

 Before installing, lightly oil outer circumference of radial-shaft seals and fill gap between sealing lips -
arrow - half way with sealing grease G 052 128 A1 .
 The open side of the gaskets points toward the fluid to be sealed in.
 Lightly lubricate O-rings before installing, this prevents the rings from being pinched when inserting.
 Check transmission oil level after replacing gaskets and seals --> Axle oil in rear final drive, checking.
Securing rings
1:13:05 AM Page 7
 Do not over-stretch circlips.

 Always replace damaged or over-stretched circlips.
 Securing rings must be fully seated in groove.
cardiagn.com
Fig. 6: Identifying Locking Elements
 Replace roll pins. Installation position: Slot - A - is longitudinal to line of force - arrow -.
Nuts, bolts
 Loosen and tighten bolts or nuts for securing covers and housings in diagonal sequence.
 Do not cant, rather loosen and tighten especially sensitive parts in diagonal manner in stages.
 The tightening torques stated apply to non-oiled nuts and bolts.
 Always replace self-locking nuts and bolts.
 Using a wire brush, clean threads of bolts (replace outer driveshaft bolts) which are secured with locking
compound. Then insert bolts with locking fluid AMV 185 101 A1 .
 Threaded bores into which self-locking bolts or bolts with locking compound were threaded in, must be
cleaned (e.g. using threaded tap). Otherwise there is the danger that the bolts may shear when removed
again.
39 - FINAL DRIVE, DIFFERENTIAL

DRIVESHAFT, SERVICING OVERVIEW
Driveshaft, servicing overview
1:13:05 AM Page 8
NOTE:  Observe general repair notes --> General Repair Notes.

 No repair work can be performed on the driveshaft - with the exception of
removing and installing and adjustment work.
 Always store and transport driveshaft fully extended only.

 If the driveshaft is only detached at the transmission or from rear

final drive, it should be tied up or supported at the shaft end.
Driveshaft must also bend without force up to the center joint stop.
 Mark positions of all parts to each other before removing. Reinstall in
identical position otherwise imbalance will be too high which could
result in damage to the bearing or in vibration noises.
 Driveshaft bolts are loosened and tightened with the parking brake
engaged.
 After disconnecting driveshaft from rear final drive, an installed
cardiagn.com
balance washer (thick washer between backing plate and hex socket
head bolt) may not be reinstalled.
Driveshaft can be bent without force up to the center joint stop. A hard
bending to the stop may cause damage to the center joint or dust boot.
 For complaints (noise, vibrations), check intermediate bearing for freedom
from tension and radial run-out of driveshaft flange at rear final drive
before replacing the driveshaft --> Measure radial play at flange/driveshaft
and mark.
1:13:05 AM Page 9
cardiagn.com
Fig. 7: Driveshaft, Servicing Overview
1 - Rear final drive
 Removing and installing Audi A4, Audi A6 --> Rear final drive, removing and installing
 Removing and installing Audi A8 --> Rear final drive (Audi A8), removing and installing
2 - Gasket
 Replace
 Pull off protective foil
 Remove grease from flange shaft and adhere seal.
3 - Driveshaft
1:13:05 AM Page 10
 Removing and installing Audi A4, Audi A6 --> Driveshaft (Audi A4 and Cabriolet, Audi A6),
removing and installing
 Removing and installing Audi A8 --> Driveshaft, removing and installing - Audi A8
4 - Balancing washer
 Not present on every vehicle

 If present, this balancing washer must no longer be installed after disconnecting driveshaft from rear final
drive.
5 - Socket head bolt, 55 Nm
 Self-locking
 Always replace
 Threaded holes for bolts in drive flanges must always be cleaned. (e.g. using a tap)
cardiagn.com
 Loosened and tightened with parking brake engaged.
6 - Backing plate
7 - Intermediate bearing
8 - Hex bolt, 25 Nm
9 - Transmission
Driveshaft (Audi A4 and Cabriolet, Audi A6), removing and installing
Special tools, testers and auxiliary items required
Fig. 8: Assembly Tool 3139

 Assembly tool 3139
1:13:05 AM Page 11
Fig. 9: Identifying Pry Lever 80-200

 Pry lever 80 - 200
cardiagn.com
Fig. 10: Identifying Engine/Transmission Jack V.A.G. 1383 A
 Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2
Driveshaft (Audi A4 and Cabriolet, Audi A6), removing
 See notes --> Driveshaft, servicing overview

 The driveshaft should only be worked on a two column lift.
Audi A4, Audi Cabriolet:
1:13:05 AM Page 12
Fig. 11: Loosening Clamping Sleeves

 Remove rear part of exhaust system from clamping sleeves - arrows - -->
cardiagn.com
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO
ENGINE MECHANICAL, ENGINE CODE(S): AMB
ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE
MECHANICAL, ENGINE CODE(S): AVK, BGN
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL,
ENGINE CODE(S): BKH
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE
MECHANICAL, ENGINE CODE(S): BNS
MECHANICAL, ENGINE CODE(S): BHF
.
Fig. 12: Using Press Lever - RMV Outside Mirror 80-200 To Pry Off Rear Attachments Of Heat Shield
For Drive Shaft & Removing Securing Bolts For Center Bearing
1:13:05 AM Page 13
 Pry off mountings - A - for heat shield above intermediate bearing.

 Remove mounting bolts for intermediate bearing - B -. When doing this, support driveshaft by hand.
 Remove heat shield while supporting driveshaft.
 Install mounting bolts for intermediate bearing by hand.
Audi A6:
cardiagn.com
Fig. 13: Removing Rear Transverse Beam & Heat Shield From Vehicle Floor
 If present, remove rear transverse beam - 1 -.

 Remove heat shield - 3 - from vehicle floor - arrows -.
Continuation for all vehicles:
Fig. 14: Removing Mounting Bolts For Front Exhaust Pipes

 If present, remove mounting bolts for front exhaust pipes - 1 - and - 2 -.
1:13:05 AM Page 14
Fig. 15: Removing/Installing Shielding Plate From Transmission

 Remove shielding plate - A - from transmission - arrows -.
cardiagn.com
 Check whether there is a marking (colored marking) on driveshaft and at flange/driveshaft at rear final
drive.
Fig. 16: Identifying Mark Position Of Driveshaft Flange To Rear Final Drive
 If this marking is not present, then mark in color the position of driveshaft flange - arrow A - to rear final
drive - arrow B -.
1:13:05 AM Page 15
Fig. 17: Attaching Alignment Fixture - 4W Dr. Shaft 3139

 Attach Alignment Fixture - 4W Dr. Shaft 3139 and tighten plastic nuts.
cardiagn.com
NOTE:  Never set alignment fixture on balance plates.
Fig. 18: Removing/Installing Securing Bolts For Center Bearing

 Remove mounting bolts - arrows - for intermediate bearing.
1:13:05 AM Page 16
Fig. 19: Locating Bolts At Transmission/Drive Shaft Flange

 Loosen securing bolts of front driveshaft - arrows -.

 Remove driveshaft from transmission and support it using engine/transmission jack V.A.G 1383 A.
cardiagn.com
Fig. 20: Removing/Installing Mounting Bolts On Rear CV Joint And Driveshaft
 Remove mounting bolts - arrows - on rear CV joint and remove driveshaft.
NOTE:  Only store and move driveshaft fully extended.
Installing driveshaft - Audi A4 and Cabriolet, Audi A6
Installation is in reverse order of removal. Note the following:
 Remove old and dry high-temperature grease from CV joints and flanges for driveshaft. Fill the exact
same amount of new grease G 000 633.
 Always remove any remaining locking fluid from thread bores in drive flanges for transmission driveshaft
and for rear final drive. Cleaning can be performed with a tap. Otherwise, the securing bolts can shear
while installing.
 After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may
be located between shim and a mounting bolt may not be reinstalled.
 Always replace (self-locking) securing bolts for driveshaft.
 Note installation position of driveshaft: Center CV joint is located behind intermediate bearing in
direction facing the rear final drive.
1:13:05 AM Page 17
 Make sure that the markings on flange for driveshaft - arrow A - and for transmission/rear final drive -
cardiagn.com
arrow B - line up.
 If a new driveshaft is installed and the factory marking on the rear final drive flange is no longer visible,
check radial run out at flange/driveshaft --> Measure radial play at flange/driveshaft and mark and
adjust color marking at new driveshaft to new marking at flange/driveshaft.
 Replace seals for driveshaft at transmission/rear final drive flange. Remove grease from sealing surfaces
and adhere new seals.
 Insert driveshaft and install with new bolts for CV joint.

 Install mounting bolts - arrows - far enough that intermediate bearing can still be moved.
1:13:05 AM Page 18

 Tighten bolts - arrows - of driveshaft at rear final drive to tightening torque.
cardiagn.com
 Tighten bolts - arrows - of front driveshaft to tightening torque.

 Remove alignment fixture 3139.
Audi A4, Audi Cabriolet:
1:13:05 AM Page 19
Fig. 25: Removing Mounting Bolts

 Remove mounting bolts - arrows -. When doing this, driveshaft must be supported by a second
cardiagn.com
technician.
Fig. 26: Installing Heat Shield, Screwing In Securing Bolts For Left/Right Center Bearing & Heat Shield
On Right/Left At Center Bearing Using Bolts
 Insert heat shield - 2 -. Continue to support driveshaft while doing this.

 Install mounting bolts - 4 - on left and right a few more turns.
 Secure heat shield - 2 - on left and right with a bolt - 1 - (M8x30) on intermediate bearing - 3 -.
NOTE:  When tightening the combination bolt - 4 - , make sure that centering
element - arrow A - is located in the locating hole - arrow B -.
1:13:05 AM Page 20
Fig. 27: Installing Heat Shield

 Tighten bolts - 2 - of intermediate bearing for driveshaft on to body free of tension. Torque
cardiagn.com
 Remove bolts - 1 -.
 Remove mounting bolts for intermediate bearing - B -. When doing this, support driveshaft by hand.
 Insert mounting clips for heat shield.
Audi A6:
Fig. 28: Tightening Bolts Of Intermediate Bearing For Driveshaft On To Body Tightening Torque
 Tighten bolts of intermediate bearing for driveshaft on to body tightening torque. While doing this,
centering elements of intermediate bearing must be located in the locating holes - arrows -.
Continuation for all vehicles:
1:13:05 AM Page 21

 Tighten bolts of shielding plate - A - on to transmission - arrows -.
cardiagn.com
Fig. 30: Removing/Installing Mounting Bolts For Front Exhaust Pipes
 If present, tighten bolts of front exhaust pipes - 1 - and - 2 -.
Fig. 31: Removing/Installing Rear Transverse Beam & Heat Shield From Vehicle Floor
1:13:05 AM Page 22
 If present, tighten bolts of heat shield - 3 - on to vehicle floor - arrows -.

 Install rear part of exhaust system - 2 - -->
ENGINE CODE(S): BKH
cardiagn.com
.
 If present, install rear transverse beam - 1 - --> 40 - FRONT SUSPENSION .
Tightening torques
Component Nm
Heat shield for driveshaft to transmission 25
Driveshaft, removing and installing - Audi A8
Fig. 32: Assembly Tool 3139

1:13:05 AM Page 23

 Engine/transmission jack V.A.G 1383 A with universal mount V.A.G 1359/2
cardiagn.com
Removing driveshaft - Audi A8
Removing
See notes --> Driveshaft, servicing overview.
NOTE:  The driveshaft should only be worked on a two column lift.
Fig. 34: Disconnecting Exhaust System At Clamping Sleeves

 Disconnect exhaust system at clamping sleeves - 1 - and - 2 -.
1:13:06 AM Page 24
Fig. 35: Removing Tunnel Braces & Rear Part Of Exhaust System
 Remove both tunnel braces - A - and - B -.
cardiagn.com
 Remove rear part of exhaust system - C - -->
ENGINE CODE(S): BKH
.
Fig. 36: Removing Heat Shield

1:13:06 AM Page 25
 Remove heat shield - arrows -.

 Remove primary catalytic converter -->
ENGINE CODE(S): BKH
cardiagn.com
.
drive - arrows A and B -.
 If these markings are not present, mark in color the position of driveshaft flange - arrow A - to rear final
drive - arrow B -.
1:13:06 AM Page 26
Fig. 38: Attaching Alignment Fixture - 4W Dr. Shaft 3139 With Spacers 3139/4
 Attach Alignment Fixture - 4W Dr. Shaft 3139 with Spacers 3139/4 and tighten plastic nuts.
cardiagn.com
NOTE:  Never set alignment fixture on balance plates.

 Remove mounting bolts - arrows - for intermediate bearing.
1:13:06 AM Page 27

 Remove heat shield - A - from transmission - arrows -.
cardiagn.com
 Loosen securing bolts of front driveshaft - arrows - , to do so engage parking brake.

 Remove driveshaft from transmission and support it using engine/transmission jack V.A.G 1383 A.

 Remove mounting bolts - arrows - on rear CV joint, to do so engage parking brake.

 Remove driveshaft.
NOTE:  Only store and move driveshaft fully extended.
Installing driveshaft - Audi A8
Installation is performed in reverse order of removal. Note the following:
1:13:06 AM Page 28
 Remove old and dry high-temperature grease from CV joints and flanges for driveshaft. Fill the exact
same amount of new grease G 000 633.
 Always remove any remaining locking fluid from thread bores in drive flanges for transmission driveshaft
and for rear final drive. Cleaning can be performed with a tap. Otherwise, the securing bolts can shear
while installing.
 Note installation position of driveshaft: Center CV joint is located behind intermediate bearing in
direction facing rear final drive.
cardiagn.com
 Make sure that the markings on flange for driveshaft - arrow A - and for transmission/rear final drive -
arrow B - line up.
 If a new driveshaft is installed and the factory marking on the rear final drive flange is no longer visible,
check radial run out at flange/driveshaft --> Measure radial play at flange/driveshaft and mark and
adjust color marking at new driveshaft to new marking at flange/driveshaft.
 Replace seals for driveshaft at transmission/rear final drive flange. Remove grease from sealing surfaces
and adhere new seals.
 Insert driveshaft and install with new bolts for CV joint.
1:13:06 AM Page 29

 Install mounting bolts - arrows - far enough that intermediate bearing can still be moved.
cardiagn.com
 Tighten bolts - arrows - of driveshaft at front and rear to tightening torque.

 Remove alignment fixture 3139.
1:13:06 AM Page 30
 Remove heat shield - A - - arrows -.
Align intermediate bearing as follows:
 Slightly loosen mounting bolt for intermediate bearing.
cardiagn.com
Fig. 47: Sliding Driveshaft Toward Front, Rear, Right, Left Until It Stops And Mark Position Of
Intermediate Bearing On Body & Aligning Driveshaft
 Slide driveshaft toward front until it stops and mark position of intermediate bearing on body - arrow A -
.
 Slide driveshaft toward rear until it stops and mark position of intermediate bearing on body - arrow B -.
 Slide driveshaft toward right until it stops and mark position of intermediate bearing on body - arrow 1 -.
 Slide driveshaft toward left until it stops and mark position of intermediate bearing on body - arrow 2 -.
 Align driveshaft - arrow C - and - arrow 3 -.
 Center bearing must stand centered between markings - arrow A - and - arrow B - , and - arrow 1 - and
- arrow 2 -.
 Tighten mounting bolts of intermediate bearing to tightening torque.
Continuation:
1:13:06 AM Page 31
Fig. 48: Removing Heat Shield

 Install heat shield above intermediate bearing - arrows -.
cardiagn.com
 Install and adjust exhaust system free of stress -->
ENGINE CODE(S): BKH
.
Fig. 49: Removing Tunnel Braces & Rear Part Of Exhaust System
1:13:06 AM Page 32
 Install both tunnel braces - A - and - B - -->

 66 EXTERIOR EQUIPMENT
 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET
Tightening torques
Component Nm
Heat shield for driveshaft to transmission 25
Driveshaft, disconnecting from rear final drive
 See notes --> Driveshaft, servicing overview

 The driveshaft should only be worked on a two column lift.
cardiagn.com
Fig. 50: Loosening Clamping Sleeves And Removing Rear Part Of Exhaust System
 Loosen clamping sleeves - 1 - and - 2 - and remove rear part of exhaust system -->
ENGINE CODE(S): BKH
.
1:13:06 AM Page 33
drive.
cardiagn.com
drive - arrow B -.

 Remove mounting bolts - arrows - on rear CV joint with parking brake engaged and remove driveshaft.
1:13:06 AM Page 34
Fig. 53: Disconnecting Driveshaft From Rear Final Drive And Tie Up To Side
 Disconnect driveshaft from rear final drive and tie up to side - arrow -.
cardiagn.com
Driveshaft, securing to rear final drive
 Remove old and dry high-temperature grease from CV joint and flange for driveshaft. Fill the exact same
amount of new grease G 000 633.
 Threaded holes in flange shaft at rear final drive must be cleaned of locking compound residue. Cleaning
can be performed with a tap. Otherwise, the securing bolts can shear while installing.
 Replace seal for driveshaft at rear final drive flange. Remove grease from sealing surfaces and adhere
new seal.
 Insert driveshaft and install bolts for CV joint.
1:13:06 AM Page 35
 Make sure that the markings on flange for driveshaft - arrow A - and for rear final drive - arrow B - line
up.
cardiagn.com
 Tighten bolts - arrows - of driveshaft at rear final drive to tightening torque.

 Install rear part of exhaust system -->
ENGINE CODE(S): BKH
.
MEASURE RADIAL PLAY AT FLANGE/DRIVESHAFT AND MARK
Measure radial play at flange/driveshaft and mark
1:13:06 AM Page 36
Fig. 56: Identifying Dial Gauge Holder VW 387

 Dial gauge holder VW 387
cardiagn.com
 Dial gauge
 Bolt M10x30
NOTE:  Radial run-out must always be measured if the flange/driveshaft at rear

final drive was removed. For this, make new color marking and remove old
color marking.
 If a new driveshaft is installed and the color marking on the drive flange of
the rear final drive is no longer visible, location of largest radial run-out
(corresponding to greatest distance from turning axis) must be determined
and marked with a color marking.
 This color marking - arrow A - is set opposite the color marking on the
driveshaft - arrow B -.
 Radial run-out can be measured with rear final drive installed.
1:13:06 AM Page 37
 Remove driveshaft from rear final drive --> Driveshaft, disconnecting from rear final drive.
Fig. 58: Securing Measuring Tools With Bolt To Rear Final Drive & Setting Dial Indicator Onto Ground
Diameter In Inside Of Driveshaft Flange
cardiagn.com
 Secure measuring tools with bolt - A - (M10x30) to rear final drive.

 Set dial indicator onto ground diameter in inside of driveshaft flange - arrow - and set to "0" with 1 mm
preload.
 Rotate both rear wheels simultaneously in one direction and thereby turn flange through one complete
rotation.
 Mark largest radial run-out on outer edge of flange with colored marking (equivalent to largest distance
from turning axis).
 Then remove previous marking from flange.

 Install driveshaft.
AXLE OIL IN REAR FINAL DRIVE, CHECKING
Axle oil in rear final drive, checking
1:13:06 AM Page 38
Fig. 59: Identifying Drip Tray V.A.G 1306

 Drip tray V.A.G 1306
cardiagn.com
Fig. 60: Identifying Torque Wrench V.A.G. 1331
 Torque wrench V.A.G 1331
Fig. 61: Removing Sealing Plug For Checking Transmission Fluid

 Remove sealing plug for checking transmission fluid - arrow -.
Oil level is correct when rear final drive is filled up to lower edge of oil filler hole.
 Transmission oil specification: Capacities and specification - Audi A4 2002 >, Cabriolet 2003 > --> Code
letters, aggregate allocation, ratios, capacities, Audi A4 2002 >, Cabriolet 2003 > , Audi A6 2005 > --
> Code letters, aggregate allocation, ratios, capacities, Audi A6 2005 > , Audi A8 2004 > --> Code
letters, aggregate allocation, ratios, capacities, Audi A8 2004 >
 Install screw plug - arrow - and tighten.
1:13:06 AM Page 39
Tightening torque: 45 Nm
REAR FINAL DRIVE, REMOVING AND INSTALLING
Rear final drive, removing and installing
Rear final drive (Audi A4 and Cabriolet, Audi A6), overview --> Rear final drive (Audi A4 and Cabriolet,
Audi A6), overview
Rear final drive (Audi A4 and Cabriolet, Audi A6), removing and installing --> Rear final drive (Audi A4 and
Cabriolet, Audi A6), removing and installing
Rear final drive (Audi A8), overview --> Rear final drive (Audi A8), overview
Rear final drive (Audi A8), removing and installing --> Rear final drive (Audi A8), removing and installing
cardiagn.com
Rear final drive (Audi A4 and Cabriolet, Audi A6), overview
1:13:06 AM Page 40
cardiagn.com
Fig. 62: Rear Final Drive (Audi A4 And Cabriolet, Audi A6), Overview
1 - Subframe
 Removing and installing --> 42 - REAR SUSPENSION
2 - Hex bolt
3 - Hex bolt, 40 Nm
 For transmission support on subframe

 If present, replace nut
4 - Hex socket head bolt, 40 Nm
1:13:06 AM Page 41
5 - Rear cross member
6 - Washer
7 - Nut
 Self-locking
 Replace
 Tightening torque --> 42 - REAR SUSPENSION
 Removing and installing --> Rear final drive (Audi A4 and Cabriolet, Audi A6), removing and
installing
9 - Drive axle
cardiagn.com
10 - Heat shield
12 - Transmission support
Rear final drive (Audi A4 and Cabriolet, Audi A6), removing and installing

1:13:06 AM Page 42

cardiagn.com
Removing
Observe general repair notes --> General Repair Notes.

ENGINE CODE(S): BKH
1:13:06 AM Page 43

.
cardiagn.com
drive.
drive - arrow B -.

 Remove driveshaft from rear final drive - arrows -.
1:13:06 AM Page 44
 Disconnect driveshaft from rear final drive and tie up to side - arrow -.
cardiagn.com
Fig. 69: Removing/Installing Right/Left Shielding Plates From Rear Final Drive
 Remove right and left shielding plates from rear final drive - arrows -.
 Remove left and right drive axles.
Fig. 70: Place Engine/Transmission Jack V.A.G 1383 A With Universal Transmission Support V.A.G
1:13:06 AM Page 45
1359/2 Under Final Drive And Secure Final Drive

 Place Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 under
rear final drive.
 Secure rear final drive using strap to universal transmission support.
cardiagn.com
Fig. 71: Removing/Installing Securing Bolts From Transmission Support
 Remove securing bolts - arrows - from transmission support.
Fig. 72: Removing/Installing Mounting Bolts From Cross Member

 Remove mounting bolts - arrow A - and - arrows B - from cross member.
Bolt - arrow A - remains in cross member.
1:13:07 AM Page 46
Fig. 73: Lowering/Raising Rear Final Drive

 Lower rear final drive slightly.
cardiagn.com
 Rotate rear final drive slightly to the side and while doing this pull drive axles out of flange shafts on
alternating sides.
 Lower rear final drive completely.
Installing rear final drive - Audi A4 and Cabriolet, Audi A6
 Rotate rear final drive to side.

 Raise rear final drive and while doing this guide in drive axles on alternating sides.
1:13:07 AM Page 47
Fig. 75: Removing/Installing Mounting Bolts From Cross Member

 First install mounting bolt - arrow A - by hand.
cardiagn.com
 Install mounting bolts - arrows B -.
 Tighten mounting bolts - arrow A - and - arrows B -.
Fig. 76: Removing/Installing Securing Bolts From Transmission Support

 Tighten securing bolts of transmission support - arrows -.
1:13:07 AM Page 48
 Install drive axles --> 42 - REAR SUSPENSION .
cardiagn.com
 Install right and left shielding plates on rear final drive - arrows -.
 Replace seal on flange/driveshaft and tighten bolts of driveshaft to rear final drive, while doing this set
markings to face each other.
 Check axle oil level in rear final drive --> Axle oil in rear final drive, checking.

ENGINE CODE(S): BKH
.
Rear final drive (Audi A8), overview
1:13:07 AM Page 49
cardiagn.com
Fig. 78: Rear Final Drive (Audi A8), Overview
1 - Subframe
2 - Hex bolt
3 - Washer
4 - Nut, 40 Nm
 Self-locking
 Replace
1:13:07 AM Page 50
6 - Rear tunnel brace
7 - Drive axle
8 - Heat shield
9 - Bolt and washer assembly, 25 Nm
10 - Transmission support
 Observe assembly sequence
cardiagn.com
11 - Hex socket head bolts, 40 Nm plus an additional 90° (1 /4 turn).
 Replace
12 - Hex socket head bolts, 40 Nm plus an additional 90° (1 /4 turn).
 Replace
13 - Not installed
14 - Not installed
15 - Not installed
16 - Not installed
 Removing and installing --> Rear final drive (Audi A8), removing and installing
18 - Nut
 Self-locking
 Replace
 Tightening torque --> 42 - REAR SUSPENSION
19 - Washer
20 - Hex bolt
1:13:07 AM Page 51
Rear final drive (Audi A8), removing and installing
cardiagn.com

 Engine/transmission jack V.A.G 1383 A with universal mount V.A.G 1359/2
Removing
1:13:07 AM Page 52
Fig. 81: Disconnecting Exhaust System At Clamping Sleeves

 Remove rear part of exhaust system from clamping sleeves - 1 - and - 2 - -->
cardiagn.com
ENGINE CODE(S): BKH
.
1:13:07 AM Page 53
drive - arrows A and B -.

 If these markings are not present, mark in color the position of driveshaft flange - arrow A - to rear final
drive - arrow B -.
cardiagn.com
 Remove driveshaft from rear final drive - arrows -.
 Tie up drive shaft to side - arrow -.
1:13:07 AM Page 54
 Remove heat shields on rear final drive - arrows -.
cardiagn.com
 Remove left and right drive axles.
 Set engine/transmission jack V.A.G 1383 A with universal mount V.A.G 1359/2 under rear final drive.
1:13:07 AM Page 55
Fig. 87: Removing/Installing Bolts For Transmission Support

 Remove bolts - arrows A and B - for transmission support.
cardiagn.com
Fig. 88: Removing/Installing Bolts For Rear Cross Member
 Remove bolts - arrows - for rear cross member.

 Lower rear final drive slightly.

 Rotate rear final drive slightly to side and while doing this pull drive axles out of flange shafts on
alternating sides.
 Lower rear final drive completely.
Installing rear final drive - Audi A8
 Rotate final drive to the side.
1:13:07 AM Page 56
 Raise rear final drive and while doing this guide in drive axles on alternating sides.

cardiagn.com
 Tighten bolts - arrows -.

 Install bolts - A - and - B - by hand (complete transmission support makes contact on final drive). Then,
first tighten bolt - A - and then bolts - B -.
1:13:07 AM Page 57
 Install heat shields on rear final drive - arrows -.
cardiagn.com
 Replace seal on flange/driveshaft and tighten bolts of driveshaft to rear final drive, while doing this set
markings to face each other.
 Check axle oil level in rear final drive --> Axle oil in rear final drive, checking.
 Install and adjust rear part of exhaust system free of stress -->
ENGINE CODE(S): BKH
.
1:13:07 AM Page 58

Tightening torques
cardiagn.com
Component Nm
Rear final drive to rear cross member - arrows - 55

Tightening torques
Rear final drive to transmission support - arrows A 40 + 90° 1)2)

and B -
Heat shields to rear final drive 25

1) Replace bolts.

1) 90° corresponds to one quarter turn.
OIL SEALS FOR FLANGE SHAFTS, REPLACING
Oil seals for flange shafts, replacing
1:13:07 AM Page 59
 Oil seals can only be replaced when transmission is removed.
cardiagn.com
Fig. 95: Puller T10037
 Puller T10037
Fig. 96: Drift VW 295

 Drift VW 295
 Driver T40108
 Sealing grease G 052 128 A1
Removing
 Observe general repair notes --> General Repair Notes.

 Remove rear final drive --> Rear final drive (Audi A4 and Cabriolet, Audi A6), removing and
installing.
Remove right drive flange
1:13:07 AM Page 60
 Place drip tray underneath.
Fig. 97: Threading Puller T10037 Tightly To Housing And Pulling Out Flange Shaft
cardiagn.com
 Thread puller T10037 tightly to housing - arrow - and pull out flange shaft.
Remove left drive flange
Fig. 98: Threading Puller T10037 Tightly To Housing And Pulling Out Flange Shaft
 Thread puller T10037 tightly to housing - arrow - and pull out flange shaft.
1:13:07 AM Page 61
Fig. 99: Prying Out Sealing Ring With Suitable Lever

 Pry out sealing ring with suitable lever.
cardiagn.com
Installing
Installing right oil seal
 Coat outer edge of gasket with axle oil.

 Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Fig. 100: Driving In New Seal To Stop, Without Canting Seal

 Drive in new seal to stop, without canting seal.
Installing left oil seal

1:13:07 AM Page 62

cardiagn.com
Fig. 102: Installing Right/Left Flange Shafts
Install right and left flange shafts
 Drive in flange shaft using centering mandrel VW 295.

 Install rear final drive.
 Axle oil in rear final drive, checking --> Axle oil in rear final drive, checking.
SEALING RING FOR FLANGE/DRIVESHAFT (REAR FINAL DRIVE INSTALLED), REPLACING
Sealing ring for flange/driveshaft (rear final drive installed), replacing
1:13:08 AM Page 63

cardiagn.com
Fig. 104: Puller VW 391
 Puller VW 391
Fig. 105: Seal Driver-Frt Wheel Bearing 3143

1:13:08 AM Page 64
 Seal driver-frt wheel bearing 3143
Fig. 106: Identifying Extractor Hook T20143

cardiagn.com
 Pulling hook T20143
 Driver T40109
 Sealing grease G 052 128 A1
 2 hex bolts M 8 x 30
Removing
 Rear final drive installed

1:13:08 AM Page 65

ENGINE CODE(S): BKH
.
 Disconnect driveshaft from rear final drive and tie up --> Driveshaft, disconnecting from rear final
drive.
cardiagn.com
 Place Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 under
rear final drive.
Fig. 109: Removing/Installing Securing Bolts At Transmission Support
1:13:08 AM Page 66
 Remove securing bolts from transmission support - arrows -.

 Lower final drive carefully until flange/driveshaft is accessible.
cardiagn.com
Fig. 110: Removing/Installing Circlip
 Remove circlip - arrow -.
CAUTION: If circlip is over-stretched or damaged, it must be replaced by a new circlip

of the same thickness.
 Install 2 hex bolts M 8 x 30 - arrow - in flange.

Fig. 111: Pulling Off Drive Shaft Flange Using Puller VW 391
 Pull off drive shaft flange using puller VW 391.
1:13:08 AM Page 67
Fig. 112: Pushing Oil Seal On Top, Outer Circumference Slightly Inward
 Carefully push oil seal on top, outer circumference - arrow - slightly inward.
cardiagn.com
Fig. 113: Prying Out Obliquely Set Oil Seal
 Then pry out obliquely set oil seal.
CAUTION: Make sure that contact surface for shaft oil seal is not damaged on the
drive pinion.
Installing

1:13:08 AM Page 68

cardiagn.com
 Heat flange/driveshaft to a maximum of 80°.
CAUTION: Wear protective gloves
Fig. 115: Driving On Flange/Driveshaft Far Enough Until Circlip Can Be Installed
 Drive on flange/driveshaft far enough until circlip can be installed.
1:13:08 AM Page 69
Fig. 116: Removing/Installing Circlip

 Install circlip - arrow -.
cardiagn.com
 Tighten securing bolts of transmission support - arrows -.

 Then install driveshaft to rear final drive.
 Axle oil in rear final drive, checking --> Axle oil in rear final drive, checking.
ENGINE CODE(S): BKH
1:13:08 AM Page 70

.
cardiagn.com
1:13:08 AM Page 71
39 FINAL DRIVE, DIFFERENTIAL

DRIVE SHAFT, SERVICING
Drive shaft, servicing
NOTE:  General repair instructions. Refer to Repair instructions.

 Drive shaft may be bent without force up to stop of the central constant
velocity joint. Further bending may cause damage to the joint or to the
boots.
 Only store and transport drive shaft extended.
 No repair work can be carried out on the drive shaft with the exception of
removing, installing and adjusting.
 If the drive shaft is only detached at the transmission or from rear final
cardiagn.com
drive then the drive shaft is to be tied-up at the constant velocity joint. The
drive shaft may also be bent without force up to the stop of the central
constant velocity joint, if necessary.
 Prior to removal mark the position of all parts in relation to each other.
Reinstall in the same positions otherwise the imbalance will be excessive;
the bearings could be damaged and humming noises may occur.
 After removing the drive shaft from the rear final drive, a thick washer that
may be located between the shim and the hexagon socket head bolt must
not be reinstalled.
 If complaints are received (noises, vibrations), it is essential to check the
radial run-out to drive flange at the rear final drive. A correct adjustment
may repair the problem. Refer to Drive shaft flange, measuring and
marking radial run-out.
1:10:51 AM
1:11:00 Page 1
cardiagn.com
Fig. 8: Exploded View Of Drive Shaft
2 - Drive shaft
 Removing and installing. Refer to Drive shaft, removing and installing.
3 - Gasket
 Replace
 Detach protective foil and stick self-adhesive side of the gasket onto flange shaft
 Degrease flange shaft
4 - Shim
1:10:51 AM Page 2
5 - Hex socket-head bolt - 55 Nm
 Self-locking
 Replace
 The tapped holes for the bolts in the flange shaft must always be cleaned (e.g. with a thread tap)
6 - Combi bolt - 23 Nm
7 - Transmission
Drive shaft, removing and installing
Special tools, testers and auxiliary equipment required
cardiagn.com
Fig. 9: Alignment Fixture-4W Dr. Shaft 3139
Fig. 10: Identifying Pry Lever 80-200

 Pressing lever 80-200
1:10:51 AM Page 3
 Bolt M8 x 30 (2x)
cardiagn.com
 Engine/transmission jack V.A.G 1383 A with universal transmission mounting V.A.G 1359/2
Removing
 See notes. Refer to Drive shaft, servicing

 Remove rear section of exhaust system as from clamp(s):
Refer to
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE
MECHANICAL, ENGINE CODE(S): AMB
MECHANICAL, ENGINE CODE(S): BPG, BWT
ENGINE CODE(S): BKH
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL,
ENGINE CODE(S): BNS
ENGINE CODE(S): BHF
; Removing and installing exhaust-system components
1:10:51 AM Page 4
Fig. 12: Using Press Lever - RMV Outside Mirror 80-200 To Pry Off Rear Attachments Of Heat Shield
For Drive Shaft & Removing Securing Bolts For Center Bearing
Use press lever - RMV outside mirror 80-200 to pry off rear attachments -A- of heat shield for drive
cardiagn.com

shaft.
 Remove securing bolts -B- for center bearing.
NOTE: When removing the securing bolts support the drive shaft by hand. Do not bend
drive shaft. Refer to Drive shaft, servicing.
 Remove heat shield. Continue supporting drive shaft.

 Screw in securing bolts for center bearing again hand-tight.
Fig. 13: Identifying Driveshaft Shield

 Remove heat shield for drive shaft off transmission -arrows-.
1:10:51 AM Page 5
Fig. 14: Driveshaft, Removing And Installing

 Check for a factory marking (colored dot) on drive shaft and on drive shaft flange on final drive at the
rear. If no colored dot is present, mark the position of the drive shaft flange -arrow A- relative to the rear
cardiagn.com
final drive -arrow B- with a colored dot.
Fig. 15: Engaging Alignment Fixture-4W dr. Shaft 3139

 Engage alignment fixture-4W dr. shaft 3139 and tighten plastic nuts.
NOTE: Never install assembly appliance onto balance plates.
1:10:51 AM Page 6

 Remove securing bolts -arrows- for the center bearing.
cardiagn.com
Fig. 17: Loosening Front And Rear Driveshaft Bolts
 Screw in bolt -3- M10 x 100 into rear final drive.

 To loosen bolts -1- of the rear and front drive shaft, counterhold with an assembly lever -2-.
 Remove securing bolts at the front constant velocity joint, detach the drive shaft and support it using
engine/transmission jack V.A.G 1383 A.
 Remove securing bolts at rear constant velocity joint and detach drive shaft.
NOTE: Only transport and store drive shaft when extended.
Installing
Installation is carried out in reverse order. Note the following:
NOTE:
1:10:51 AM Page 7

 To avoid imbalance, the flanges of the drive shaft -arrow A- and of the rear
cardiagn.com
final drive -arrow B- must be installed so that the factory color markings or
the markings made subsequently are in line.
 If a new drive shaft is installed and if the factory color marking on the
flange of the rear final drive is no longer visible, the radial run-out on the
drive shaft flange must be measured. Refer to Drive shaft flange,
measuring and marking radial run-out and the color marking on the drive
shaft placed in line with the new marking on the flange.
 Replace gaskets on flange shafts (detach protective foil and stick gasket
onto flange shaft).
 Remove the old and dry high-temperature grease from the constant
velocity joints and the flanges for the drive shaft. Replace with the exact
same quantity of new high-temperature grease G 000 633.
 Note the installation position of the drive shaft: The central constant
velocity joint is located behind the center bearing facing toward the rear
final drive.
 After removing the drive shaft from the rear final drive, a thick washer that
may be located between the shim and the bolt head must not be
reinstalled.
 It is essential that the locking fluid remaining in the threads in the flange
shafts on the transmission and rear final drive is cleaned out after
removing the drive shaft. Otherwise there is a danger that the new bolts
will seize when they are screwed in and then shear if they have to removed
later.
 The threaded holes can be cleaned with a thread tap.
 Replace drive shaft bolts (self-locking).
 Install drive shaft and attach bolts for constant velocity joint.
1:10:51 AM Page 8

 Screw in securing bolts -arrows- for center bearing hand-tight.
cardiagn.com
Fig. 20: Loosening Front And Rear Driveshaft Bolts
 Screw in bolt -3- M10 x 100 into rear final drive.

 To tighten bolts -1- of the rear and front drive shaft, counterhold with an assembly lever -2-.
1:10:51 AM Page 9
 Remove assembly device 3139

 Remove securing bolts -arrows- for the center bearing. The drive shaft must be supported manually by a
second mechanic.
NOTE: When removing the securing bolts support the drive shaft by hand. Refer to
Drive shaft, servicing.
cardiagn.com
Fig. 22: Installing Heat Shield, Screwing In Securing Bolts For Left/Right Center Bearing & Heat Shield
On Right/Left At Center Bearing Using Bolts
 Install heat shield -2-. Continue supporting drive shaft.

 Screw in securing bolts -4- for left and right center bearing several turns.
 Secure heat shield -2- on right and left at the center bearing -3- using bolts -1- (M8x30).
NOTE: When tightening the combination bolt -4- make sure that the center plug -arrow
A- is located at the securing bore -arrow B-.
Fig. 23: Installing Rear Securing Clips For Heat Shield

1:10:51 AM Page 10
 Tighten securing bolts -2- for the center bearing.

 Install rear securing clips for the heat shield.
 Remove bolts -1-
 Install exhaust system and align stress-free:
Refer to
cardiagn.com
ENGINE CODE(S): BKH
ENGINE CODE(S): BNS
ENGINE CODE(S): BHF
Tightening torques
Component Nm
Intermediate bearing on body 23
Drive shaft to transmission 55
Drive shaft to rear final drive 55
Heat shield for drive shaft to transmission 25
Drive shaft flange, measuring and marking radial run-out
1:10:51 AM Page 11
Fig. 24: Identifying Dial Gauge Holder VW 387

 Universal dial indicator bracket VW 387
cardiagn.com
 Dial indicator
 Bolt M10 x 85
NOTE:  The radial run-out must always be measured when the drive shaft flange
on the rear final drive has been removed. Affix a new colored dot and
remove the old color marking.
 If a new drive shaft is installed and if the marking on the flange shaft of the
rear final drive is no longer visible, the position of maximum radial run-out
must be determined and marked by a colored dot.
 The colored dot on the drive shaft is positioned opposite the above
colored dot. Refer to Installing.
 The radial run-out can be measured when rear final drive is installed but
the drive shaft must be disconnected at rear final drive. See notes. Refer to
Drive shaft, servicing
1:10:51 AM Page 12
cardiagn.com
Fig. 25: Install Measuring Tools (Vehicles With Threaded Hole In Facing Side Of Rear Final Drive)
 Secure universal dial indicator holder VW 387 with dial indicator at rear final drive.
 Position dial indicator on ground diameter in drive shaft flange -arrow- and set to "0" with 1 mm preload.
 Rotate differential by turning the two rear wheels (left and right-hand flange shafts) simultaneously in one
direction until the drive shaft flange has undergone one complete revolution.
 Mark the position of greatest radial run-out on flange exterior by a colored dot (equates to greatest
distance from rotational axis).
 Remove old marking from drive shaft flange.

 Install drive shaft. Refer to Drive shaft, removing and installing.
GEAR OIL LEVEL IN REAR FINAL DRIVE, CHECKING
Gear oil level in rear final drive, checking
1:10:51 AM Page 13

cardiagn.com
 Place drip tray V.A.G 1306 underneath.
Fig. 27: Identifying Sealing Plug For Gear Oil Inspection Plug
 Remove screw plug -1- to gear oil control.
The oil level is correct when rear final drive is filled to lower edge of filler hole.
 Top off with gear oil, if necessary:
Specification. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD.
 Install screw plug.
Tightening torque
Component Nm
1:10:51 AM Page 14
Screw plug 35
FLANGE SHAFT OIL SEALS, REPLACING
Flange shaft oil seals, replacing
cardiagn.com
Fig. 28: Fitting Drift 2062
 Driver 2062

 Observe general repair instructions. Refer to Repair instructions
NOTE: The illustration shows the left-hand side of the rear final drive. The procedure
1:10:51 AM Page 15
for removing and installing the joint flange and sealing ring on the right-hand
side is identical.
Removing
cardiagn.com
Fig. 30: Removing/Installing Heat Shields From Final Drive
 Remove heat shields from final drive -arrows-.

 Disconnect drive axle.
Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle
 Place drip tray underneath to collect oil.
Fig. 31: Removing/Installing Flange Shaft Bolt

 Remove securing bolt for flange shaft, then screw two bolts into the flange and counterhold the flange
shaft using the assembly lever.
 Pull out flange shaft.
1:10:51 AM Page 16
Fig. 32: Removing Flange Shaft Oil Seals

 Pry out flange shaft oil seals using a suitable lever.
cardiagn.com
Installing
 Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.
 Lightly oil outer circumference of seal.
Fig. 33: Driving In New Flange Seal

 Drive new seal in onto stop, for this purpose do not cant seal.
 Insert flange shaft.
 Fasten flange shaft with cone head bolt.
 Top off gear oil in rear final drive and check oil level. Refer to Gear oil level in rear final drive,
checking.
 Attach drive axles.
1:10:51 AM Page 17
Fig. 34: Removing/Installing Heat Shields From Final Drive

cardiagn.com
 Attach heat shields to final drive -arrows-.
Tightening torques
Component Nm
Drive flange on rear final drive 25
Heat shields on rear final drive 23
DRIVE SHAFT FLANGE SEAL, REPLACING
Drive shaft flange seal, replacing
1:10:51 AM Page 18
cardiagn.com
Fig. 35: Identifying Special Tools - Drive Shaft Flange Seal, Replacing
The following special tools and testing devices are required:
 V.A.G 1383A Engine/transmission jack with universal mounting V.A.G 1359/2

 3028 - Retainer
 VW 391 -Puller
 VW 771 - Slide hammer-complete set
 VW 771/37 Additional part for VW 771

 3026 - Mandrel
1:10:51 AM Page 19
Fig. 36: Drive Pinion 3143

 Drive pinion 3143
cardiagn.com
 Observe general repair instructions. Refer to Repair instructions
Removing
Refer to
ENGINE CODE(S): BKH
ENGINE CODE(S): BNS
ENGINE CODE(S): BHF
1:10:51 AM Page 20
Fig. 37: Markings On Driveshaft Flange (Dots)

 Check whether there is a factory marking (paint dot) on drive shaft. If you do not find one, mark the
position of the constant velocity joint -arrow A- relative to the rear final drive -arrow B-with a colored dot
cardiagn.com
 Disconnect drive shaft from rear final drive and tie it up to exhaust system brackets. Refer to Drive shaft,
removing and installing.
 Place engine/transmission jack V.A.G 1383 A with universal transmission mounting 1359/2 under final
drive and secure final drive.

 Remove securing bolts -arrows- of left final drive support.

 Carefully lower final drive until flange is freely accessible.
 Color-mark the position of the securing nut for the drive pinion.
Calculate dimension "a" and dimension "b"
1:10:51 AM Page 21
cardiagn.com
Fig. 39: Determining Dimension "A" And Dimension "B"
 Distance of flange to drive pinion =
Dimension a
 Distance of flange to securing nut for the drive pinion =
Dimension b
 Note calculated dimensions

 Count turns when unscrewing the securing nut and make a note of them.
NOTE: Illustrations show the final drive removed for the following procedure.
Fig. 40: Screw On Retainer 3028 And Unscrew Securing Nut For Drive Pinion
1:10:51 AM Page 22
 Install support tool 3028 and remove drive pinion nut.

cardiagn.com
Fig. 41: Pull Off Flange Using Puller VW 391
 Detach flange with removal tool VW 391.
A - Screw in two hex bolts M8 x 30 into flange.
Fig. 42: Pulling Out Sealing Ring

 Remove sealing ring.
Installing
1:10:51 AM Page 23
Fig. 43: Inserting O-Ring

 Replace O-ring between drive pinion bearing and flange.
cardiagn.com
 Lightly oil O-ring before installing.
Fig. 44: Driving In Seal For Driveshaft Flange

 Drive in seal for drive shaft flange onto stop with drift 3026.
1:10:51 AM Page 24
Fig. 45: Driving Drive Shaft Flange Onto Drive Pinion

 Drive shaft flange onto drive pinion until securing nut can be mounted.
cardiagn.com
NOTE: Use the old hex nut to reattach the flange to the drive pinion. Otherwise the
original installed position will not be relocated.
 Clean drive pinion nut and threads on drive pinion of oil and grease residues. Thinly coat threads with
locking fluid D 000 600.
NOTE: The number of turns when reattaching must be the same as during unscrewing.
Fig. 46: Checking Dimension "A" And Dimension "B"

Perform control measurement - check dimension "a" and dimension "b". Refer to Calculate dimension "a"
1:10:52 AM Page 25
and dimension "b" onward.
NOTE:  O-ring -1- must be installed when measuring.

 The hex nut must be returned to exactly the marked position.
 Maximum permissible deviation from original measurements: ± 0.3 mm.
cardiagn.com
Fig. 47: Locking Drive Pinion Hexagon Nut
 Lock hex nut.

 Move final drive back to installation position.

 Screw final drive to front mounting bracket -arrows-.

checking.
 If there was a factory marking at the drive shaft determine now the radial run-out at the flange/drive shaft.
Refer to Drive shaft flange, measuring and marking radial run-out. Attach drive shaft in such a way
that the color coding at the drive shaft are aligned with new marking at flange.
 If the position of the drive shaft relative to the flange/drive shaft were marked before removal the drive
1:10:52 AM Page 26
shaft must be reattached at same position. Refer to Drive shaft, removing and installing.
Observe installation instructions. Refer to Drive shaft, servicing
 Replace seal on drive shaft flange and tighten drive shaft to torque. Refer to Drive shaft, removing and
installing.
 Stress-free alignment of exhaust system:
Refer to
cardiagn.com
ENGINE CODE(S): BKH
ENGINE CODE(S): BNS
ENGINE CODE(S): BHF
Tightening torques
Component Nm
Front transmission support on final drive 40
Drive shaft on rear final drive 55
REAR FINAL DRIVE, REMOVING AND INSTALLING
Rear final drive, removing and installing
1:10:52 AM Page 27

 Engine/transmission jack V.A.G 1383 A with universal transmission mounting V.A.G 1359/2
cardiagn.com
Removing
Refer to
ENGINE CODE(S): BKH
ENGINE CODE(S): BNS
ENGINE CODE(S): BHF
1:10:52 AM Page 28
Fig. 50: Markings On Driveshaft Flange (Dots)

 Check whether there is a factory marking (paint dot) on drive shaft. If you do not find one, mark position
of the drive shaft flange -arrow A- relative to rear final drive -arrow B- with a colored dot.
cardiagn.com
 Remove drive shaft from rear final drive. Refer to Drive shaft, removing and installing
Fig. 51: Tying Drive Shaft To Exhaust System Bracket Using Wire
 Tie drive shaft to exhaust system bracket using a wire.

 Remove heat shields for drive axles at final drive.
 Remove drive axles from left and right from the flanges of the rear final drive.
1:10:52 AM Page 29
Place engine/transmission jack V.A.G 1383 A with universal transmission mounting 1359/2 under rear
cardiagn.com

final drive and secure rear final drive.

 Remove securing bolts of mounting bracket of rear final drive -arrows-.
1:10:52 AM Page 30
Fig. 54: Removing Nuts From Left/Right Of Cross Piece

 Remove nuts -arrows- from left and right of cross piece.

 Pull bolts out of subframe as far as possible.
NOTE: The bolts remain in the subframe.
 Slightly lower rear section of final drive.

 Move drive axles clear toward top.
 Lower rear section of final drive.
cardiagn.com
Fig. 55: Removing/Installing Securing Bolts From Crossmember
 If rear final drive is replaced then remove rear cross piece -arrows-.
Installing
NOTE:  Always replace self-locking nuts.

 It is essential that the residues of locking fluid are cleaned out from the
threaded holes in flange shaft on the rear final drive after removing the
drive shaft. Otherwise there is a danger that the new bolts will seize and
then shear when removing them again.
 The threaded holes can be cleaned with a thread tap.
 Replace drive shaft bolts (self-locking).
 Replace gaskets on flange shaft (detach protective foil and stick gasket
onto flange shaft).
1:10:52 AM Page 31

 To prevent imbalance, the flanges must be installed so that the paint
cardiagn.com
markings align -arrows A and B-. Install drive shaft. Refer to Installing.
 When lifting rear final drive, position drive axle onto flange shaft.
 Lift final drive past the right-hand drive axle until installation position.
NOTE: All components must move freely.
Fig. 57: Pushing Rear Final Drive At Left-Hand Drive Axle Upward & Constant Velocity Joint Of Drive
Axle Outward Until Limit Stop And Lower Toward Flange Shaft
 Push rear final drive at left-hand drive axle upward -arrows A-.
 While doing so push constant velocity joint of the drive axle outward until limit stop -arrow B- and lower
toward flange shaft -arrow C-.
1:10:52 AM Page 32

 Remove securing bolts of mounting bracket of rear final drive -arrows-.
cardiagn.com
 Push bolts in subframe into cross piece until limit stop.
Fig. 59: Removing Nuts From Left/Right Of Cross Piece

 Secure nuts on left and right at cross piece -arrows-.
Observe installation instructions. Refer to Drive shaft, servicing
 Replace seal on drive shaft flange and tighten drive shaft to torque. Refer to Drive shaft, removing and
installing.
 Attach drive axles.
checking.
 Install exhaust system and align stress-free:
1:10:52 AM Page 33
Refer to
ENGINE CODE(S): BKH
ENGINE CODE(S): BNS
ENGINE CODE(S): BHF
cardiagn.com
Tightening torques
Component Nm
Rear final drive to cross member -arrows- 55
Rear final drive to cross member -arrows- 55
Component Nm
Rear final drive to mounting bracket -arrows- 40
Drive shaft to rear final drive 55
Heat shields to rear final drive 23
Rear final drive, attaching to assembly bracket
Fig. 60: Holding Fixture VW 540
1:10:52 AM Page 34
 Holding fixture VW 540
Secure complete rear final drive on a repair stand with bracket VW 540
cardiagn.com
Fig. 61: Clamp Rear Final Drive In Assembly Fixture
REAR FINAL DRIVE, DISASSEMBLING AND ASSEMBLING
Assembly overview
1:10:52 AM Page 35
cardiagn.com
Fig. 62: Rear Final Drive, Overview
1 - Final drive housing
2 - Spacer sleeve
 Replace
3 - Flange for drive shaft
 Removing and installing. Refer to Drive pinion, removing and installing and disassembling and
assembling
4 - Pinion shaft
1:10:52 AM Page 36
 Is mated with ring gear, replace together as a set

 Removing and installing. Refer to Drive pinion, removing and installing and disassembling and
assembling
5 - Final drive cover
6 - Differential
 Removing and installing. Refer to Differential, removing and installing

 Disassembling and assembling. Refer to Differential, disassembling and assembling
7 - Ring gear
 Paired with pinion shaft (final drive set)

 Removing and installing. Refer to Differential, disassembling and assembling.
cardiagn.com
DIFFERENTIAL, REMOVING AND INSTALLING
Differential, removing and installing
NOTE:
1:10:52 AM Page 37
cardiagn.com
Fig. 63: Rear Differential, Overview
 General repair instructions. Refer to Repair instructions.

 Adjustments are required when replacing components marked 1). Refer to Adjustment overview.
Secure final drive on a repair stand. Refer to Rear final drive, attaching to assembly bracket.
1 - Vent sleeve
 With rubber valve

 Installation position. See Fig. 67.
2 - Final drive housing 1)
1:10:52 AM Page 38
 Removing and installing drive pinion. Refer to Drive pinion, removing and installing and
disassembling and assembling.
3 - Outer race for large taper roller bearing 1)
4 - Shim "S1"
 Note thickness
 Adjustment overview. Refer to Adjustment overview.
5 - Cover for final drive 1)
 With O-ring
cardiagn.com
 Replace O-ring
 Insert O-ring with oil
6 - TORX-screw - 25 Nm
7 - Seal, right
 Replacing. Refer to Flange shaft oil seals, replacing.
9 - Flange shaft, right
 Removing and installing. See Fig. 65
10 - Oil filler plug - 35 Nm
 Checking gear oil level in rear final drive. Refer to Gear oil level in rear final drive, checking
11 - Differential with ring gear 1)
 Disassembling and assembling. Refer to Differential, disassembling and assembling
12 - Oil drain plug, 35 Nm
13 - Socket
 Holds solenoid in position

 Drive in onto stop
1:10:52 AM Page 39
14 - Solenoid
15 - Outer race for small taper roller bearing 1)
16 - Shim "S2"
 Note thickness
 Adjustment overview. Refer to Adjustment overview
17 - Seal, left
 Replacing. Refer to Flange shaft oil seals, replacing.
18 - Flange shaft, left
cardiagn.com
 Removing and installing. See Fig. 65
20 - Cap
 Installing. See Fig. 66
Secure final drive on repair stand
Fig. 64: Clamping Rear Final Drive In Assembly Fixture

Removing and installing flange shaft
1:10:52 AM Page 40
Fig. 65: Removing/Installing Drive Flange

Press in cover until stop
cardiagn.com
Fig. 66: Pressing In Cover Up To Stop
Installation position vent sleeve
Fig. 67: Installed Location Of Breather Sleeve

1:10:52 AM Page 41
The vent sleeve must protrude from the housing by 13 mm (dimension -a-) after being pressed in.
The slot in rubber valve is located longitudinally in direction of travel.
Removal
 Rear final drive removed
cardiagn.com
 Clamp complete rear final drive into assembly bracket VW 540. Refer to Rear final drive, attaching to
assembly bracket.
 Drain gear oil.

1:10:52 AM Page 42
 Remove left and right-hand flange shafts.
 To loosen the securing bolt, screw two bolts into flange shaft and counter-hold with a lever.
 Mark flange shafts (left and right) and pull out.
 Remove securing bolts from cover for final drive.
 Take cover for final drive off axle housing and remove differential.
Installing
Installation is in reverse order.
 Insert differential.
 Replace O-ring for cover for final drive and oil when installing.
 Install cover for final drive onto axle housing and using diagonal sequence tighten to 25 Nm.
cardiagn.com
 Fill space between sealing lip and dust lip with a thin layer of sealing grease G052 128 A1.

 Insert flange shafts and tighten to 25 Nm.

checking.
DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
Differential, disassembling and assembling
1:10:52 AM Page 43
cardiagn.com
Fig. 71: Identifying Special Tools - Differential, Disassembling And Assembling (1 Of 2)
The following special tools and testing devices are required:
 Thrust plate VW 401

 Thrust plate VW 402
 Punch VW 407
 Thrust disc VW 412
 Needle bearing drift VW 295

 Punch VW 408 A
1:10:52 AM Page 44
cardiagn.com
Fig. 72: Identifying Special Tools - Differential, Disassembling And Assembling (2 Of 2)
 Thrust pad VW 442

 Sleeve 40-21
 Thrust piece 40-105
 Thrust plate 2050
 Drift 3138
 Two-arm puller Kukko 44/2
1:10:52 AM Page 45
Fig. 73: Tapered Roller Bearing Puller V.A.G 1582

 Taper roller bearing extractor V.A.G 1582
cardiagn.com
Fig. 74: Tapered Roller Bearing Puller V.A.G 1582
 V.A.G 1582/6
NOTE:
1:10:52 AM Page 46
cardiagn.com
Fig. 75: Rear Differential, Overview
 General repair instructions. Refer to Repair instructions.

 Secure final drive on a repair stand. Refer to Secure complete rear final
drive on a repair stand with bracket VW 540.
 Replace both taper roller bearings together.
 When replacing the parts marked with 1) adjustment work is required.
Refer to Adjustment overview.
1 - Cover for final drive 1)
2 - O-ring
 Replace
1:10:53 AM Page 47
 Insert with oil
4 - Shim "S1"
 Note thickness
 Tapping out. See Fig. 76

 Pressing in. See Fig. 77
6 - Inner race for small taper roller bearing 1)
cardiagn.com
 Pulling off. See Fig. 78
 Pressing on. See Fig. 79
7 - Bolt - 60 Nm plus an additional45°1/4 turn
 Replace
 Allocation
 Lightly tighten bolts then tighten diagonally to specified torque.
8 - Differential housing 1)
9 - Ring gear 1)
 Paired with pinion shaft (final drive set)

 Allocation based on transmission code letters
 Drive off housing with a drift. See Fig. 84

 Install to differential housing. See Fig. 85
10 - Spring pin
 For securing shaft for bevel gears

 Drive in flush
11 - Inner race for large taper roller bearing 1)
1:10:53 AM Page 48

13 - Shim "S2"
 Note thickness
14 - Threaded piece
15 - Large bevel gear
cardiagn.com
 Adjusting. See Fig. 87
16 - Small bevel gear
17 - Shaft for planet wheels
 Drive out with drift
18 - Adjustment shim
 Redefine thickness. See Fig. 87
19 - Thrust washer
 Check for cracks
Driving small taper roller bearing outer race out of cover
1:10:53 AM Page 49
Fig. 76: Driving Small Tapered Bearing/Outer Race Out Of Housing

 After removing check shims for damage.
cardiagn.com
Pressing in taper roller bearing outer race small until stop into housing
Fig. 77: Pressing Small Tapered Bearing/Outer Race Into Housing To Stop
Pulling off inner race for small taper roller bearing
1:10:53 AM Page 50
cardiagn.com
Fig. 78: Pulling Off Small Inner Race/Tapered Bearing
A - Two arm puller, e.g. Kukko 44/2
Pressing on small taper roller bearing inner race
Fig. 79: Pressing On Small Tapered Bearing Inner Race

WARNING: WARNING!
1:10:53 AM Page 51
Wear protective gloves!
 Heat inner race to approx. 100°C, position and push to final position.
Pulling off inner race for large taper roller bearing
cardiagn.com
Fig. 80: Pulling Off Large Inner Race/Tapered Bearing
 Install thrust plate 40-105 onto differential housing before installing puller.
Pressing on large taper roller bearing inner race
Fig. 81: Pressing On Inner Race Of Large Taper Roller Bearing

WARNING: WARNING!
Driving out outer race for large taper roller bearing out of cover
1:10:53 AM Page 52
Fig. 82: Driving Off Outer Race/Tapered Bearing From Cover

cardiagn.com
Pressing in outer race for large taper roller bearing into cover
Fig. 83: Pressing Outer Race/Tapered Bearing Into Cover

Driving ring gear off housing
Fig. 84: Driving Out Ring Gear From Housing
1:10:53 AM Page 53
Installing ring gear
Fig. 85: Installing Ring Gear
cardiagn.com
WARNING: WARNING!
 Locate ring gear guide with centering pins -A- (self-produced) when mounting.
 Heat ring gear to approx. 100°C and position.
Installing small bevel gears
Fig. 86: Installing Small Differential Bevel Gears

 If large bevel gears have been replaced, measure and select new shims. See Fig. 87.
 Insert large bevel gears with recalibrated shims.
 Insert small bevel gears spaced 180° apart, and then rotate into place -arrow-.
 Insert washers and align.
1:10:53 AM Page 54
 Insert threaded pieces.

 Drive small bevel gear shaft into final position and secure.
Adjusting differential bevel gears
cardiagn.com
Fig. 87: Differential Planetary Gears, Adjusting
 Insert large bevel gears with thinnest shims (0.5 mm).

 Insert small bevel gears at a 180° offset with thrust washers.
NOTE: Do not now interchange bevel gears and thrust washers.
 Drive in shaft for bevel gears.

 Press small bevel gears outward.
 Press large bevel gears in direction of -arrow- and check play.
 Ascertain the thickest - just fitting - shim for large bevel gears on each side.
 Select required shims from table. Part numbers
The following shims are available:
Shim thickness (mm)

0.50 0.70 0.90
0.60 0.80 1.00
NOTE:
1:10:53 AM Page 55
cardiagn.com
Fig. 88: Installing Differential Bevel Gear Shim
The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the
differential bevel gears -arrow-.
DRIVE PINION, REMOVING AND INSTALLING AND DISASSEMBLING AND ASSEMBLING
Drive pinion, removing and installing and disassembling and assembling
1:10:53 AM Page 56
cardiagn.com
Fig. 89: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And
Assembling (1 Of 4)
Special tools and workshop equipment required
 VW 391 Puller
 VW 401 Thrust plate
 VW 402 Thrust plate
 VW 407 Punch
 VW 408 A Punch
 VW 412 Thrust disc
1:10:53 AM Page 57
cardiagn.com
Assembling (2 Of 4)
 VW 457 Supporting channels

 VW 460 Removal device
 VW 470/1 Assembly ring
 VW 519 Sleeve
 VW 540 Holding fixture

 30-205 Thrust pad
1:10:53 AM Page 58
cardiagn.com
Assembling (3 Of 4)
 2003/3 Inserter ring

 3005 Thrust pad
 3028 Retainer
 3062 Thrust pad
 3138 Drift
 3143 Seal driver-Frt wheel bearing
1:10:53 AM Page 59
cardiagn.com
Assembling (4 Of 4)
 VW 771 Slide hammer-complete set

 3026 Mandrel
 3253 Wheel bearing assembly set
 V.A.G 1383 A Engine/transmission jack
NOTE:
1:10:53 AM Page 60
cardiagn.com
Fig. 93: Exploded View Of Drive Pinion Assembly
 Replace both taper roller bearings together.

 Install new taper roller bearings in delivery condition and do not oil
additionally.
 When replacing the parts marked with 1) adjustment work is required.
1 - Nut
 Unscrewing. See Fig. 94

 Screwing in. See Fig. 108
 Measuring friction torque. See Fig. 109
 Securing. See Fig. 110
1:10:53 AM Page 61
2 - Flange for drive shaft

3 - Sealing ring
 Pulling out. See Fig. 96

 Tapping in. See Fig. 106
4 - O-ring
 Replace
 Insert with gear oil. See Fig. 105
cardiagn.com
5 - Inner race for small taper roller bearing 1)
 Pressing out drive pinion. See Fig. 97

 Pulling out. See Fig. 98

7 - Spacer sleeve 1)
 Replace
9 - Shim "S3"
 Note thickness

 Inserting. See Fig. 102
11 - Inner race for large taper roller bearing 1)
 Pressing off. See Fig. 100

1:10:53 AM Page 62
12 - Drive pinion 1)
 Is mated with ring gear, replace together as a set
Removing nut for drive pinion
cardiagn.com
Fig. 94: Removing/Installing Nut For Pinion
 Secure final drive on a repair stand. Refer to Secure complete rear final drive on a repair stand with
bracket VW 540.
 Screw in two hexagon nuts M8 x 30 -A-.
B - Socket, long A/F 36
 When nut is loosened the final drive must be supported (e.g. with universal transmission mounting 1359/2
in conjunction with engine/transmission jack V.A.G 1383 A).
Pulling flange for drive shaft off drive pinion
Fig. 95: Pull Off Flange Using Puller VW 391

 Screw two hex nuts M8 x 30 -A- into the flange.
1:10:53 AM Page 63
Pulling out seal for flange for drive shaft
Fig. 96: Pulling Out Sealing Ring

cardiagn.com
Pressing drive pinion out of inner race for small taper roller bearing
Fig. 97: Pressing Off Drive Pinion From Inner Race/Tapered Bearing
Pulling out small taper roller bearing outer race
1:10:54 AM Page 64
Fig. 98: Pulling Off Small Outer Race/Tapered Bearing

B - Support, e.g. Kukko 22/2
B - Internal puller 46 to 2.28 in, e.g. Kukko 21/7
Driving out outer race for large taper roller bearing
cardiagn.com
Fig. 99: Driving Out Large Outer Race/Tapered Bearing
Pressing inner race for large taper roller bearing off drive pinion
Fig. 100: Pressing Off Inner Race Of Large Taper Roller Bearing
A - Separating device 22 to 4.53 in, e.g. Kukko 17/2
Pressing inner race for large taper roller bearing onto drive pinion
1:10:54 AM Page 65
Fig. 101: Pressing On Inner Race Of Large Taper Roller Bearing

cardiagn.com
WARNING: WARNING!
Pulling in outer race for large taper roller bearing
Fig. 102: Pulling In Large Outer Race/Tapered Bearing

 Lightly lubricate bearing seat in housing.

 Insert predetermined shim "S3" for drive pinion. Refer to Adjustment overview.
The inscription "top" on pressure plate 3253/4 faces nut of insertion device
Pressing in small taper roller bearing outer race
1:10:54 AM Page 66
Fig. 103: Pressing In Small Outer Race/Tapered Bearing

 Lightly lubricate the bearing seat in the housing.
cardiagn.com
 The outer race must be attached with needle bearing drift VW 295 and thrust pad 30-205.
Pressing on small taper roller bearing inner race
Fig. 104: Installing Small Taper Roller Bearing Inner Race

 Insert new drive pinion with a new spacer sleeve.
WARNING: WARNING!
 Heat inner race for small taper roller bearing to approx. 100°C and install onto drive pinion.
 Press up drive pinion and insert bearing with sleeve 40-21 onto stop.
Inserting O-ring
1:10:54 AM Page 67
Fig. 105: Inserting O-Ring

 Insert O-ring with gear oil.
cardiagn.com
Tapping in seal for flange for drive shaft
Fig. 106: Driving In Seal For Driveshaft Flange


 Drive in seal onto stop with Mandrel 3026.
Installing flange
1:10:54 AM Page 68
Fig. 107: Driving Drive Shaft Flange Onto Drive Pinion

 Drive shaft flange onto drive pinion until securing nut can be mounted.
cardiagn.com
Tighten nut for drive pinion and adjusting friction torque
Fig. 108: Removing/Installing Nut For Pinion

 Screw in two hex nuts M8 x 30 -A-.
B - Socket, long A/F 36
 When the nut is tightened the final drive must be supported (e.g. with universal transmission mounting
1359/2 in conjunction with engine/transmission jack V.A.G 1383 A).
NOTE: Only increase tightening torque slowly and read-off frictional torque frequently.
If the specified frictional torque is exceeded, the spacer sleeve must be
replaced and the adjustment repeated. It is not possible to re-use a spacer
sleeve that has been excessively compressed.
Measuring frictional torque
1:10:54 AM Page 69
Fig. 109: Measuring Friction Torque

NOTE: Do not lubricate new taper roller bearings for frictional torque measurement.
cardiagn.com
The bearings have already been treated with special oil by the manufacturer.
With torque gauge, 0 to 600 Ncm, standard commercially available
B - Socket, A/F 36
NOTE: Use 3/4" to 1/2" reducer as necessary.
The following frictional torques should be set:
New bearings Used bearings 1)

200 to 250 Ncm 30 to 60 Ncm
1) With at least 50 km service
Removing nut for drive pinion
Fig. 110: Locking Drive Pinion Hexagon Nut

1:10:54 AM Page 70
 When the nut has been locked the radial run-out on the drive shaft flange should be measured. Refer to
Drive shaft flange, measuring and marking radial run-out.
DRIVE PINION AND RING GEAR, ADJUSTING
Drive pinion and ring gear, adjusting
NOTE:  Careful adjustment of the drive pinion and ring gear is important for the
service life and smooth running of the final drive. For this reason, the drive
pinion and ring gear are matched together during manufacture, and
checked to ensure a good mesh pattern and quiet running in both
directions of rotation. The position of quietest running is found by moving
the drive pinion in an axial direction and at the same time lifting the ring
gear out of the zero-play mesh position by the amount necessary to
maintain the backlash within the specified tolerance.
cardiagn.com
 The object of the adjustment is to reproduce the setting for quietest
possible running, as obtained on the test machine in production.
 The deviation "r", which is related to the master gauge "Ro" is measured
for the final drive sets supplied as replacement parts and marked on the
outer circumference of the ring gear. The final drive set (drive pinion and
ring gear) must only be replaced together as a matched pair.
 Observe the general repair instructions for taper roller bearings and
shims.
 Maximum care and cleanliness are essential for achieving good results
when performing repairs and taking measurements.
Gear sets, adjusting and marking
1:10:54 AM Page 71
cardiagn.com
Fig. 111: Identifying Gear Set Markings And Adjustment Dimensions
1 - Marking "0937" indicates Oerlikon final drive set with transmission ratio 37 : 9.
NOTE: Klingelnberg final drives "K937" or Gleasen final drives "G937" can be installed.
2 - Gear set pairing number (312).
3 - Deviation (tolerance) "r" is based on the test machine master gauge used in production. The deviation
"r" is always given in 1/100 mm. Example: "25" means r = 0.25 mm
Ro - Length of adjustment master "Ro" of tester used.
Ro - Ring gear = 57.50 mm
1:10:54 AM Page 72
cardiagn.com
Fig. 112: Identifying Gear Set Markings And Adjustment Dimensions
R - Actual dimension between ring gear and face of pinion shaft at point with quietest running for this
gear set. R = Ro + r
Vo - Hypoid offset
Position of shims
1:10:54 AM Page 73
cardiagn.com
Fig. 113: Identifying Differential Adjustment Shim Positions
NOTE: Adjustment overview when Replacing individual components of transmission.

S1 - Adjustment shim for ring gear in cover for final drive
S2 - Shim for ring gear in final drive housing
S3 - Shim for drive pinion in final drive housing
Adjustment overview
NOTE: If performing assembly work on the final drive it is only necessary to adjust the
drive pinion or final drive set if components have been replaced which have a
1:10:54 AM Page 74
direct effect on the adjustments of the final drive. To eliminate unnecessary

adjustments observe following table:
To adjust:
Ring gear Pinion shaft Backlash
Parts replaced: "S1"+"S2" 1) "S3" 1) Testing
? Refer to Ring gear, Using deviation "r" Refer to Adjusting
adjusting Refer to Drive pinion, backlash
adjusting
Final drive housing X X X
Differential housing X X
Taper roller bearings for X X
pinion shaft
Taper roller bearing for X X
differential
cardiagn.com
Final drive set 2) X X X
Final drive cover X X
1) Shims; installation position. Refer to Position of shims.
2) Drive pinion and ring gear; only replace together.
Final drive, readjustment sequence
The following procedure is recommended to save time when the drive pinion and ring gear have to be adjusted:
1.) Determine total shim thickness "Stotal" for "S1" + "S2" for the specified preload for taper roller
bearings for differential.
2.) Determine total shim thickness "S3" to reproduce the installation position for the drive pinion
determined on the test machine in production.
3.) Distribute total shim thickness "Stotal" for "S1" + "S2" so that the specified backlash exists between
ring gear and drive pinion.
NOTE: Overview of components and shims. Refer to Position of shims.
Drive pinion, adjusting
1:10:54 AM Page 75
Fig. 114: Universal Measuring Device VW 385

 VW 385 Universal measuring tool
cardiagn.com
Fig. 115: Holding Fixture VW 540
 VW 540 Engine and transmission support
NOTE:  Before adjusting the drive pinion adjust the ring gear (ascertain total shim
thickness "S" for shims "S1" + "S2"). Refer to Ring gear, adjusting.
 Re-adjustment of the drive pinion is only necessary if the final drive set,
taper roller bearing for drive pinion or housing for final drive is replaced.
Adjustments. Refer to Adjustment overview.
 Do not oil new taper roller bearings for frictional torque measurement. The
bearings have already been treated with special oil by the manufacturer.
Determining shim "S3" thickness
(Setting preload of taper roller bearing for drive pinion)
 Clamp final drive into assembly bracket. Refer to Rear final drive, attaching to assembly bracket.
1:10:54 AM Page 76
 Insert both outer races for the taper roller bearing without shims into the housing. Refer to Fig. 102 and
Fig. 103
Fig. 116: Installing Small Taper Roller Bearing Inner Race
cardiagn.com
 Insert drive pinion without spacer sleeve.

 Heat inner race for taper roller bearing to approx. 100°C and install onto drive pinion.
WARNING: WARNING!
NOTE:  Only install spacer sleeve for final frictional torque measurement (after
determining shim "S3").
 Install new taper roller bearings in delivery condition and do not oil.
 Mount flanges for drive shaft and tighten hex nut for the flange. Refer to Fig. 107
Fig. 117: Measuring Friction Torque

1:10:54 AM Page 77
A - Torque gauge, commercially available, 0 to 600 Ncm
B - Socket, A/F 36
 Tighten drive pinion nut until the following frictional torque is obtained.

200 to 250 Ncm 30 to 60 Ncm
cardiagn.com
Fig. 118: Setting Adjusting Rings Of Measuring Bar VW 385/1
 Set adjustment ring of universal mandrel VW 385/1.
 Distance a = 60 mm
 Set sliding adjustment ring.
 Distance b = 55 mm
Fig. 119: Assemble Measuring Bar According
1:10:55 AM Page 78
 Assemble universal mandrel as illustrated.
 Dial indicator extension VW 385/15 = 9 mm long
 Set universal master gauge VW 385/30.
 Ro = 57.50 mm
 Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.

 Turn drive pinion 8 turns in both directions so that the taper roller bearings settle.
cardiagn.com
Fig. 120: Placing Magnetic Plate Onto Drive Pinion Face
 Place end measuring plate VW 385/33 onto drive pinion head.
1:10:55 AM Page 79
Fig. 121: Insert Measuring Mandrel In The Housing

 Remove master gauge and insert measuring mandrel in the housing.
 The centering disc for VW 385/3 faces toward cover for final drive
 Install cover for final drive and tighten 4 bolts.

 Using adjustable ring, move 2nd centering disc out as far as possible so that the mandrel can still just be
turned by hand.
Determining measurement "e"
cardiagn.com
Fig. 122: Insert Universal Mandrel And Perform Check Measurement
 Turn mandrel until the dial indicator point touches the end measuring plate on pinion shaft head, then
measure maximum deflection (return point). The measured value is dimension "e" (in red range).
 Measurement in following example: "e" = 1.60 mm
NOTE: Dimension "e" is required to determine thickness of shim "S3".
 Then, (after removing universal mandrel) check again that the dial indicator, with master gauge VW
385/30 installed, indicates "0" with 2 mm preload, otherwise repeat the measurement.
Determining shim thickness "S3"
Formula:
"S3" = "e" - "r"
e = Determined value
r = Deviation (marked on ring gear in 1 /100 mm)
1:10:55 AM Page 80
Example:
Determined value "e" 1.60 mm
- Deviation "r" 0.42 mm
= Thickness of shim "S3" 1.18 mm
 Determine shim(s) as accurately as possible from table. Part numbers
The following shims are available for "S3"
Shim thickness (mm) 1)

0.95 1.20 1.45
1.00 1.25 1.50
1.05 1.30 1.55
1.10 1.35
cardiagn.com
1.15 1.40
1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if
necessary.
 Remove universal mandrel.

 Remove drive pinion and outer race for large taper roller bearing and reinstall with calibrated shims "S3"
and spacer sleeves. Refer to Fig. 94.
 Insert inner race for small taper roller bearing and tighten drive pinion nut until specified frictional torque
is achieved. Refer to Fig. 108.
NOTE:  Do not oil new taper roller bearings for frictional torque measurement. The
 Only increase tightening torque slowly and read-off frictional torque
frequently. If the specified frictional torque is exceeded, the spacer sleeve
must be replaced and the adjustment repeated. It is not possible to re-use
a spacer sleeve that has been excessively compressed.
 Set to following frictional torques:

200 to 250 Ncm 30 to 60 Ncm
Performing check measurement
Checking dimension "r"
1:10:55 AM Page 81
 Turn drive pinion 8 turns in both directions so that the taper roller bearings settle.
cardiagn.com
Fig. 123: Insert Measuring Mandrel In The Housing
 Insert universal mandrel and check measurement.
 If the shims have been correctly selected, the dial indicator, reading counter clockwise (in red range), will
show deviation "r" within a tolerance of ± 0.05 mm
 Peen drive pinion nut with a punch.

 The radial run-out at flange for drive shaft must always be measured and marked. Refer to Drive shaft
flange, measuring and marking radial run-out.
Ring gear, adjusting
1:10:55 AM Page 82
cardiagn.com
Fig. 124: Identifying Special Tools - Ring Gear, Adjusting
(Adjusting differential)
 VW 385/17 Magnetic plate 50 mm dia.

 VW 387 Dial gauge holder
 VW 388 Measuring lever
 VW 521 Adjustment tool for ring gear
 V.A.G 1331 Torque wrench
It is necessary to readjust the ring gear when:
1:10:55 AM Page 83
Final drive housing, cover for final drive, taper roller bearing for differential, differential housing or
drive pinion are replaced.
Adjustment overview. Refer to Adjustment overview
NOTE:  Differential taper roller bearings are low friction bearings. Therefore the
frictional torque only has a limited use as a check. Correct adjustment is
only possible by determining the total shim thickness "Stotal".
Determining total shim thickness "Stotal" for shims "S1" + "S2"
(Setting preload of taper roller bearing for differential)
cardiagn.com
 Drive pinion is removed!
NOTE: If only the taper roller bearings for the differential are being replaced, the ring
gear can be removed from the differential housing. The pinion shaft does not
need to be removed.
 Pry out seals for flange shaft using a suitable lever.

 Remove outer races of differential taper roller bearings and remove shims. Refer to Differential,
disassembling and assembling
 Drive outer race/taper roller bearing for left differential (housing side) with shim "S2*" of thickness 1.00
mm into housing. Refer to Differential, disassembling and assembling.
NOTE: For measurement purposes a shim "S2" with a thickness of 0.04 in is initially
inserted. It is referred to as "S2*" in the following. After determining the
backlash "S2*" will be replaced by the correct "S2".
 Drive outer race/taper roller bearing for right differential (cover side) without shim in onto stop. Refer to
Differential, disassembling and assembling.
 Insert differential into housing. The ring gear is positioned on the right side (cover side).
 Install cover and tighten bolts to 25 Nm.
1:10:55 AM Page 84
Fig. 125: Installing Special Tools VW 521/4 And 521/8 Onto Housing Side In Differential Housing
 Install special tools VW 521/4 and 521/8 onto housing side in differential housing.
cardiagn.com
 Turn cover side of differential housing upward.
 Turn differential 8 turns in both directions so that the taper roller bearings settle.
 Place measuring plate VW 385/17 onto differential.
Fig. 126: Installing Measuring Tools

 Install measuring tools.
A - Dial indicator extension approx. 30 mm long
B - Hex bolt M8 x 45
 Position dial indicator extension in middle of measuring plate VW 385/17.

 Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
1:10:55 AM Page 85
cardiagn.com
Fig. 127: Read Play On Dial Gauge
 Lift differential without turning; read off play on dial indicator and write it down.
 Measurement in following example: 0.50 mm
 If you want to repeat the measurement differential 8 turns in both directions so that the taper roller
bearings settle.
Determine "Stotal" (S1 + S2)
Formula:
"Stotal" = "S2*" + measurement + bearing preload
Example:
Inserted shim(s) "S2*" 1.00 mm
+ Measurement 0.50 mm
+ Bearing preload (constant) 0.30 mm
= Total shim thickness "Stotal" 1.80 mm
for shims "S1" + "S2"
Determining thickness of shim "S1*"
NOTE:  The preliminary adjustment shim "S1*" will be replaced with the final shim
"S1" after determining the backlash.
 The total shim thickness "Stotal" remains the same.
1:10:55 AM Page 86
Formula:
"S1*" = "Stotal" - "S2*"
Example:
Total shim thickness "Stotal" 1.80 mm
for shims "S1" + "S2"
- Inserted shim(s) "S2*" 1.00 mm
= Thickness of shim "S1*" 0.80 mm
 Define shim(s) as precisely as possible based on the table. Refer to The following shims are available
for "S1".
Measuring frictional torque (check)
 Pinion shaft removed
cardiagn.com
 Differential installed with shims "S1*" and "S2*"
Fig. 128: Measuring Differential Frictional Torque

 Install torque gauge 0 to 600 Ncm -A- onto differential.

 Read off friction torque.
Frictional torque specified values:

150 to 300 Ncm 30 to 60 Ncm
NOTE:  Differential taper roller bearings are low friction bearings. Therefore the
frictional torque only has a limited use as a check. Correct adjustment is
only possible by determining the total shim thickness "Stotal".
1:10:55 AM Page 87
 If the final drive set is being re-adjusted, the adjustment of the pinion shaft
should be performed now, and the adjustment should be checked. Refer to
Drive pinion, adjusting.
Adjusting backlash
 Drive pinion with shim "S3" installed

 Differential with shims "S1*" + "S2*" installed
 Insert differential into final housing mount cover and tighten all bolts to 25 Nm.
cardiagn.com
 Install measuring tools.

 Use dial indicator extension VW 382/10 (6 mm flat).
 Set measuring lever VW 388 to dimension "a" = 60 mm.
 Measure play between teeth flanks (backlash) as follows:
 Turn ring gear until it makes contact with a tooth flank (end of backlash travel).
 Preload dial indicator to 1 mm and set to zero.
 Turn ring gear back until lying against an opposite tooth flank (backlash).
 Read off backlash and note value.
 Turn ring gear through 90° and repeat measurements a further 3 times.
Determining average backlash
Example:
1:10:55 AM Page 88
1st Measurement 0.28 mm

+ 2nd Measurement 0.30 mm
+ 3rd Measurement 0.30 mm
+ 4th Measurement 0.28 mm
= Sum of measured values 1.16 mm
 Result: The average backlash is 1.16 divided by 4 = 0.29 mm
NOTE: If the individual measurements differ by more than 0.06 mm from each other,
the installation of the ring gear or the final drive set itself is not correct. Check
installation; replace final drive set, if necessary.
Determining thickness of shim "S2"
Formula:
cardiagn.com
"S2" = "S2*" - backlash + lift
Example:
Inserted shim "S2*" 1.00 mm
- Average backlash 0.29 mm
+ Lift (constant) 0.15 mm

0.15 0.50 1.50
0.20 0.80
0.25 1.00
necessary.
Determining thickness of shim "S1"
Formula:
"S1" = "Stotal" - "S2"
Example:
Total shim thickness "Stotal" 1.80 mm
for "S1" + "S2"
1:10:55 AM Page 89
- Thickness of shim "S2" 0.86 mm


0.15 0.50 0.90
0.20 0.60 1.00
0.30 0.70 1.20
0.40 0.80
necessary.
cardiagn.com
Check measurement

 Drive pinion with shim "S3" installed

 Differential with shims "S1" (cover side) + "S2" (housing side) installed
 Measure backlash four times on circumference.
 Specification: 0.12 to 0.22 mm
NOTE:  If the backlash is beyond the tolerance, the adjustments must be repeated.
Refer to Determining thickness of shim "S2". The total shim thickness
"Stotal" must not be changed.
 The individual measurements must not differ by more than 0.06 mm from
1:10:56 AM Page 90
each other.
cardiagn.com
1:10:56 AM Page 91

A4 Rear Differential Rear Final Drive

Uploaded by

Copyright:

Available Formats

A4 Rear Differential Rear Final Drive

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

A4 Rear Differential Rear Final Drive

Uploaded by

Copyright:

Available Formats

2005 Audi A4 Quattro

REAR DIFFERENTIAL Rear Final Drive

00 GENERAL, TECHNICAL DATA

 5-Speed Manual Transmission 01A, AWD

 Automatic Transmission 01V, AWD

Fig. 1: Locations Of Final Drive Identification

Location on final drive

Code letters and date of manufacture (arrow 1)

Final drive 01R (arrow 2)

Fig. 2: Final Drive 01R

Final drive 01R (arrow 2)

Code letters and manufacturing data for the final drive

Additional data is production-related

CODE LETTERS, TRANSMISSION RATIOS, CAPACITIES

Allocation of mechanical units: 5-speed Manual Transmission 01A AWD

Rear final drive 01R

Code letters ETT ETS

Allocation of mechanical units: 6-speed Manual Transmission 01E, AWD

Allocation of mechanical units: 6-speed Manual Transmission 02X, AWD

Rear final drive 01R

Allocation of mechanical units: 6-speed Manual Transmission 0A3, AWD

Rear final drive 01R

Rear final drive 01R

Allocation of mechanical units: Automatic Gearbox 09L, AWD

Rear final drive 01R

Specification Axle oil G 052 145 A1 (container

6 - Front drive pinion (output shaft)

10 - Rear drive pinion

Arrows in direction of travel

Arrows in direction of travel

Gaskets, sealing rings

Fig. 6: Identifying Space Between Oil Seal Sealing Lips

 Replace spring pins.

Installation position: Slot longitudinal to line of force.

Rear Final Drive 0AR

00 - GENERAL, TECHNICAL DATA

Identification of rear final drive

Rear Final Drive 0AR is allocated to the following transmissions:

 6-speed Manual Transmission 02X

Allocation at rear final drive

Fig. 1: Locating Final Drive 0AR & Identification/Date Of Construction

Final Drive 0AR - arrow 1 -

Identification and date of construction - arrow 2 -

Final Drive 0AR - arrow -

Code letters and date of manufacture of rear final drive

Further data can be ignored.

Rear final drive 0AR

Rear final drive 0AR

Code letters, aggregate allocation, ratios, capacities, Audi A6 2005 >

Rear final drive 0AR

Rear final drive 0AR

POWER TRANSFER, OVERVIEW

Power transfer, overview

 Depicted with 6 speed manual transmission 0A3 All Wheel Drive.

NOTE:  Arrows in direction of travel

4 - Input shaft (main shaft)

6 - Front pinion shaft (output shaft)

10 - Rear drive pinion