Self-locking center differential cover, removing and installing

WARNING: This page is about a different car, the 2010 Audi A8, 2009 Audi A8, 2008 Audi A8, 2007 Audi A8, and 2004 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Drip Tray V.A.G 1306

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray V.A.G 1306
Safety glasses

Removing

Transmission installed.

CAUTION: Do not let engine run or tow vehicle without gear oil.

NOTE:

General repair notes → General Repair Notes .
Rules of cleanliness for working on automatic transmissions → Rules of cleanliness for working on automatic transmissions .

Vehicles with one front exhaust pipe:

Fig 2: Locating Clamping Sleeve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Flex joint in front exhaust pipe must not be bent more than 10° , otherwise it may be damaged.

Disconnect exhaust system at double clamp - arrow -.

Fig 3: Center Front Exhaust Pipe Bracket Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts - arrows - on center front exhaust pipe bracket.

Vehicles with two front exhaust pipes:

Fig 4: Exhaust System Clamping Sleeves

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate exhaust system at clamping sleeves - 1 - and - 2 -.

Fig 5: Front Muffler Retaining Straps Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Flex joint in front exhaust pipe must not be bent more than 10° , otherwise it may be damaged.

Remove nuts - arrows - on front exhaust pipe retaining tabs.

All:

Fig 6: Removing/Installing Heat Shield For Driveshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt heat shield - A - for drive shaft - arrows -.
Remove bolts at transmission/drive shaft flange.
Push drive axle toward rear final drive. CV joints can be moved axially.
Tie drive shaft up to side.

Fig 7: Loosening/Tightening Self-Locking Center Differential Cover Bolts In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

CAUTION: Wear eye protection.

Loosen and remove self-locking center differential cover bolts in - 6 to 1 - sequence and drain gear oil.

NOTE:

The cover has no oil drain plug, so the gear oil can only be drained by removing cover.

CAUTION: Carefully pull self-locking center differential cover off transmission toward the rear. Otherwise, the self-locking center differential can fall out of the transmission.

Fig 8: Securing Self-Locking Center Differential And Baffle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure self-locking center differential - B - and baffle - A - against falling out or remove from output shaft toward rear.

Installing

Installation is in reverse order of removal, note the following:

NOTE:

Replace transfer case cover O-ring.

Fig 9: Self-Locking Center Differential And Baffle Installation Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If self-locking center differential - B - and baffle - A - were removed:

Clean baffle, lubricate with gear oil and insert into transmission.

Installation position: The plate - A - on baffle must be secured with side tabs via opening - B - on transmission.

Fig 10: Securing Self-Locking Center Differential And Baffle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place self-locking center differential - B - on output shaft splines while rotating slightly.

NOTE:

Check installation location of baffle with plate again - arrow -.
Check whether installed self-locking center differential can be turned by hand.
Check whether baffle plate - arrow - is still secured correctly.
Place cover with shaft installed on self-locking center differential, rotating slightly if necessary.

Fig 11: Loosening/Tightening Self-Locking Center Differential Cover Bolts In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten self-locking center differential cover bolts as follows:

Stage	Tightening
I	Tighten bolts - 1 - and - 2 - to 3 Nm.
II	Tighten bolts - 1 through 11 - in sequence listed to 23 Nm.

Install drive shaft → 39 FINAL DRIVE, DIFFERENTIAL for 01R or 39 - FINAL DRIVE, DIFFERENTIAL for 0AR .
Install exhaust system →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
.
Fill gear oil in transfer case → Gear oil in transfer case, topping off after repair .

Torque specifications

Component	Nm
Self-locking center differential cover to transmission housing	23
Cross member to body	23
Heat shield for drive axle to transmission	23