Final drive/transmission housing seal, replacing

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: Identifying Special Tools - Final Drive/Transmission Housing Seal, Replacing

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Drip tray V.A.G 1306
Extractor lever VW 681
Thrust piece T10139

Conditions

Transmission removed.
Transmission attached to assembly stand → Transmission, attaching to assembly stand .

CAUTION: The transmission must not be set down on the ATF cooler or oil pan.

Work procedure

NOTE:

A faulty seal will allow gear oil to enter the torque converter bell housing.
General repair notes → General Repair Notes .
Rules of cleanliness for working on automatic transmissions → Rules of cleanliness for working on automatic transmissions .

Place drip tray V.A.G 1306 underneath transmission.
Remove right flange shaft → Right flange shaft, removing and installing .

For vehicles with ATF cooler on transmission:

Fig 2: ATF Cooler Components

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Remove bolts - 4 - , - 6 - , - 7 -.

NOTE:

Bolts - 4 - , - 6 - , - 7 - secure bracket - 5 - for ATF cooler - 8 - on transmission.

Place bracket - 5 - together with ATF cooler - 8 - at top.

All:

Fig 3: Removing/Installing Bolts On Final Drive Cover In Sequence

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Remove final drive cover bolts in - 11 to 1 - sequence and remove cover together with tapered roller bearing outer race and shim.

NOTE:

The shim must be the correct size and must not be replaced by a shim with a different thickness.

Remove differential.

Fig 4: Identifying Tapered Roller Bearing Outer Race For Differential And Shim

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Remove differential tapered roller bearing outer race - 1 - and shim - 2 - located behind it from transmission housing by hand.

NOTE:

The shim must be the correct size and must not be replaced by a shim with a different thickness.

Remove left flange shaft → Left flange shaft, removing and installing .

Fig 5: Removing Sealing Ring

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Remove sealing ring.

NOTE:

Extractor Lever VW 681 must be positioned behind both sealing lips of the sealing ring. Do not position at outer circumference of sealing ring, otherwise the contact surface in transmission housing will be damaged. Guide the lever carefully when prying the seal.

Examine oil seal seat in transmission housing for damage; if necessary rework.
Coat outer circumference and sealing lip of seal with gear oil.

NOTE:

Push seal onto pressure piece so that the projecting sealing lip of seal faces the tool.

Fig 6: Driving In New Oil Seal As Far As Stop Using Thrust Piece T10139

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Drive in new sealing ring as far as stop with Thrust Piece T10139.

Fig 7: Identifying Tapered Roller Bearing Outer Race For Differential And Shim

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Insert shim - 2 - and differential tapered roller bearing outer race - 1 - into transmission housing up to stop by hand.

NOTE:

Do not tilt shim and outer race when inserting.

Fig 8: Differential Cover O-Ring

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Replace O-ring - arrow -.
Insert differential into transmission housing.

If outer race for taper roller bearing and shim have fallen out of cover for final drive:

Lubricate shim and outer race for taper roller bearing with gear oil and insert into final drive cover as far as the stop.

Fig 9: Removing/Installing Bolts On Final Drive Cover In Sequence

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Tighten final drive 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.

Fig 10: ATF Cooler Components

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Install bracket - 5 - together with ATF cooler - 8 -

Install left flange shaft → Left flange shaft, removing and installing .
Install right flange shaft → Right flange shaft, removing and installing
Check oil level in front final drive → Gear oil level in front final drive .