Torsen differential cover, removing and installing

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2009 Audi A4, 2008 Audi S4, 2008 Audi A4, 2007 Audi S4, and 2007 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Drip Tray V.A.G 1306

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray V.A.G 1306
Safety goggles

Removing

Transmission installed

CAUTION: The engine must not run and the vehicle must not be towed without gear oil.

NOTE:

General repair instructions → General repair instructions .
Read the rules for cleanliness when working on the automatic transmission → Rules for cleanliness .

Fig 2: Locating Clamping Sleeve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles with 2.0 ltr. TFSI engine

NOTE:

The flexible line connection (de-coupling element) on the front exhaust line must not be bent more than 10° - otherwise it can be damaged.

Loosen nuts on front clamp - arrows -.
Push clamp toward rear of vehicle to disconnect exhaust system.

Fig 3: Locating Clamping Sleeves

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles with 4.2 ltr. MPI engine:

NOTE:

To prevent damage, the flexible couplings in the front exhaust lines must not be bent further than 10°.

Disconnect exhaust system at clamps - arrows -.
Disengage rear section of exhaust system at rubber mountings and remove.

NOTE:

A second technician is required for removing the rear section of the exhaust system.

Fig 4: Removing/Installing Heat Shield For Driveshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove heat shield - A - for driveshaft - arrows -.
Remove bolts at transmission/driveshaft flange.
Slide driveshaft together toward rear final drive. The constant velocity joints can be moved axially.

Fig 5: Drive Shaft Tied To Side, Onto Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tie driveshaft to side, onto heat shield - arrow -.

Fig 6: Loosening/Tightening Securing Bolts For Cover For Torsen Differential In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place drip tray V.A.G 1306 under transmission.

CAUTION: Wear safety goggles.

Loosen securing bolts for cover for Torsen differential in sequence - 6 to 1 - and remove; allow gear oil to drain out.

NOTE:

The cover is not equipped with a drain plug; drain gear oil by removing the cover.

CAUTION: Pull the Torsen differential cover backward from the transmission housing slowly and carefully. The Torsen differential may otherwise fall out of the transmission.

Fig 7: Securing Torsen Differential And Baffle Plate To Prevent Them From Dropping Out

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure Torsen differential - B - and baffle plate - A - to prevent them from dropping out, or pull them off output shaft toward the rear.

Fig 8: Identifying If Torsen Differential And Baffle Plate Have Been Removed

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

Installation is performed in reverse sequence. Note the following:

NOTE:

Replace O-ring on cover for transfer gear.

Note the following if the Torsen differential - B - and the baffle plate - A - have been removed:

Clean baffle plate, lubricate with gear oil and insert in transmission.

Installation position: tongue on baffle plate should be positioned on the transmission so that the side lugs are located above opening - B - - arrow -.

Fig 9: Securing Torsen Differential And Baffle Plate To Prevent Them From Dropping Out

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install Torsen differential - B - onto splines of output shaft (turn slightly at the same time).

NOTE:

Check installation position of tongue on baffle plate - arrow - again.

Check whether the attached Torsen differential can be turned manually.
Check whether tongue - arrow - on baffle plate is still located properly.
Place cover for Torsen differential with shaft installed onto Torsen differential, turn slightly if necessary.

Fig 10: Loosening/Tightening Securing Bolts For Cover For Torsen Differential In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten bolts of cover for Torsen differential as follows.

Step	Tightening sequence
I	Tighten bolts - 1 - and - 2 - to 3 Nm.
II	Tighten bolts - 1 to 6 - to 23 Nm in the sequence indicated.

Install driveshaft →
- 39 FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE
- 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR
.
Install exhaust system free of stress →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO 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
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
.
Top off transfer gear oil→ Transfer gear oil, topping off after repairs

Tightening torques

Component	Nm
Cross member to body	23
Heat shield for drive axle to transmission	23