oil AUDI A8 1996 D2 / 1.G 01V Transmission Center Differential Service Workshop Manual

39-46


WARNING!
Do not run engine with the center differential
removed or without gear oil and do not tow
vehicle.
Notes:
The parts listed in the following illustration can be
removed with the transmission installed.
4020 press tube
3118 press support
Item 3 Kukko 17/2 separating tool
Rules of cleanliness for working on automatic
transmissions page 37
-148
.
General repair notes page 00
-27
.
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39-57


- Unbolt driveshaft -1- from transmission and let rest on heat shield -2-
page 39
-79
, Driveshaft, removing and installing.
- Secure driveshaft using wire (arrow) at bracket -3- of fuel lines.
- Drain center differential gear oil page 39
-40
.

WARNING!
Carefully pull center differential housing off of transmission toward
rear. The Torsen differential could otherwise fall out of the
transmission. - Loosen mounting bolts (arrows) for center differential housing in
diagonal sequence and remove.
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39-58


Installing
Installation is reverse of removal, noting the following: - Pull Torsen differential off output shaft toward rear.

Note:
Lightly coat sealing surface -D- with gear oil to prevent the seal from
slipping. - Check for alignment bushing (arrow A) and (arrow B).
- Install gasket
- Slide cleaned magnet into cast holding pocket -1- in intermediate
flange.
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39-59

- Add 200 ml. gear oil to output housing
(comparable to gear oil, topping up on removed
and disassembled center differential page 39
-
43
).

- Install Torsen differential onto splines of output shaft and bottom spur
gear while turning slowly.
- Check whether installed Torsen differential can be turned by hand.

- Install fully assembled transfer housing with installed spur gears and
rear drive flange onto transmission flange.
- Insert bolts for transfer housing and tighten to final tightening torque in
diagonal sequence in several stages.
- Bolt driveshaft to transmission flange page 39
-79
, Driveshaft,
removing and installing.
- Fill transfer housing with gear oil and check oil level page 39
-40
.
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39-62


- Unbolt driveshaft -1- from transmission and let rest on heat shield -2-
page 39
-79
, Driveshaft, removing and installing.
- Secure driveshaft using wire (arrow) at bracket -3- of fuel lines.
- Drain center differential gear oil page 39
-40
.

- Unbolt output flange while securing output flange against turning using
a drift.
- Pull out output flange.
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39-64

Installing
Installation is reverse of removal, noting the
following:

Tightening torques - Drive O-ring in to stop using 3402 pressure piece.
- Secure output flange with socket-head bolt.
- Bolt driveshaft to transmission flange page 39
-79
, Driveshaft,
removing and installing.
- Fill transfer housing with gear oil and check oil level page 39
-40
.
Component
Nm
Socket-head bolt for rear drive flange 25
Heat shield for driveshaft to transmission 23
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39-65

Seal in intermediate flange for front final
drive, replacing


Note:

An inspection opening is provided on the left side of the intermediate
flange to check for oil leaks (arrow) for the seal in drive pinion and the
seal in intermediate flange.
If oil escapes at this inspection opening, this double seal must be
replaced.
Special tools and equipment

3404 thrust piece
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39-67

Seal in drive pinion, replacing


Note:

An inspection opening is provided on the left side of the intermediate
flange to check for oil leaks (arrow) for the seal in drive pinion and the
seal in intermediate flange.
If oil escapes at this inspection opening, this seal must be replaced.
Special tools and equipment

Removing
3403 thrust piece
- Remove center differential page 39
-56
.
- Remove intermediate flange for front final drive.
- Carefully pull off drive pinion from driveshaft.
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