Final Drive 0BC Removing And Installing, AUDI Q635 Hybrid: Removing

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Pay attention to the safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the general repair information. Refer to REPAIR INFORMATION .

-- Place the vehicle on a lift.

De-energizing the High-Voltage System

WARNING:

Follow the High-Voltage System General Warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

Turning off the voltage in the high-voltage system is carried out exclusively via the Guided Fault Finding on the Vehicle Diagnostic Tester.

CAUTION:

Extremely dangerous high-voltage

Electrocution can cause death or very serious personal injury.

The high-voltage system may only be turned off by a qualified person (Audi high-voltage technician).
It must be certain that the voltage for the high-voltage system is de-energized. The de-energized state is determined exclusively with the Vehicle Diagnostic Tester via the "Guided Fault Finding".
The qualified technician (Audi high-voltage technician) will make sure the voltage is turned off and that the system cannot turn back on again using a Service Disconnect Lock T40262. The qualified technician should make sure the system cannot turn on again by keeping the key and the High-Voltage System Maintenance Connector -TW- in a safe place.
The qualified personnel (Audi high-voltage technicians) mark the vehicle with a label.

NOTE:

De-energizing the high-voltage system:

Connect the Vehicle Diagnostic Tester

Select the Guided fault finding mode

Using the Go To button, move through the following menu points

Function/component selection

Body

Electrical Equipment

OBD-capable system

8C - hybrid battery management -J840

8C - hybrid battery management, functions

51 - De-energize the high-voltage (Repair Group 93) 93)

-- Remove the wheel hubcap from the left rear wheel. On alloy wheels, remove the cap using the puller in the vehicle tool kit.

-- Remove the left rear wheel.

-- loosen the clamping sleeves -1 and 2- and remove the rear section of the exhaust system. Refer to EXHAUST PIPES/MUFFLERS, SEPARATING .

Fig 1: Exhaust System Clamping Sleeves

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NOTE:

A second technician is needed to help remove the rear section of the exhaust system.

-- Remove the driveshaft from the rear final drive. Refer to DRIVESHAFT, REMOVING AND INSTALLING FROM REAR FINAL DRIVE .

Fig 2: Removing/Installing Driveshaft Bolts

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-- Remove the driveshaft intermediate bearing mounting bolts -arrows-.

Fig 3: Identifying Driveshaft Intermediate Bearing Mounting Bolts

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-- Push the driveshaft forward and at the same time remove it from the rear final drive.

NOTE:

The driveshaft is supported by the heat shield under the intermediate bearing.

The driveshaft can be bent all the way to the center joint without force. Bending the joint forcibly all the way can damage the center joint and/or the protective boot.

-- Secure the driveshaft on the side to the subframe.

-- Remove the bolt -3- for the potential equalization cable -2-.

Fig 4: Removing Bolt From Potential Equalization Cable

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-- Remove the left driveshaft heat shield -A- from the crossmember/rear final drive -arrows-.

Fig 5: Removing Left Driveshaft Head Shield

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-- Remove the left -1- and right -3- driveshafts.

Fig 6: Removing Left And Right Driveshaft

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-- Loosen the bolts -2- approximately three turns.

-- Remove the bolt -4-.

-- Position the Engine and Gearbox Jack VAS6931 and the Universal Transmission Support VAG359/2 and a block of wood -A- (approximately 80 mm tall) under the rear final drive.

Fig 7: Placing Jack And A Block Of Wood Under Rear Final Drive

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NOTE:

Pay attention that the Universal Transmission Support VAG359/2 does not make contact with the fuel tank.

-- Remove the bolts -1- (lower bolts attaching the crossmember to the rear final drive) and -2-.

-- Remove the two upper bolts that connect the crossmember -B- to the rear final drive.

Fig 8: Guiding T40154 Through Holes In Subframe -A-

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-- Guide the Socket - Xzn 12 T40154 through the holes in the subframe -A-. Move the final drive to the left or right just a little, if necessary.

-- Move the final drive -A- forward slightly.

Fig 9: Placing VAG 1383 A With VAG 1359/2 And A Block Of Wood

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-- Turn the lower crossmember -B- direction of -arrow 1- and guide the final drive -arrow 2- and remove it.

NOTE:

A second technician must help with the next steps.

Before raising the left rear suspension, secure the vehicle to the lifting arm on the hose using a Tensioning Strap T10038.

-- Remove the Engine and Gearbox Jack VAS6931 from under the final drive while a second technician keeps the rear final driving from falling down.

-- Insert the Engine/Gearbox Jack Adapter - Wheel Hub Support T10149 in the Engine and Gearbox Jack VAS6931.

-- Attach the Engine/Gearbox Jack Adapter - Wheel Hub Support T10149 using a wheel bolt -arrow A- to the left rear suspension wheel hub.

Fig 10: Attach T10149 To Suspension Left Rear Wheel Hub Using A Wheel Bolt

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-- Lift the left rear suspension using the Engine and Gearbox Jack VAS6931 just until the support arm -1- on the vehicle hoist just starts to lift the vehicle -arrow B-.

WARNING:

Do not raise or lower the vehicle when the Engine and Gearbox Jack VAS6931 is underneath it.
Do not leave the Engine and Gearbox Jack VAS9631 under the vehicle longer than necessary.

-- The second technician must now push the rear final drive -1- toward the left side of the vehicle in direction of -arrow-.

Fig 11: Mount Rear Final Drive On Subframe

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-- Then guide the right driveshaft -5- upward out of the final drive flange shaft -4-.

-- Guide the left driveshaft -3- out and then, together with the second technician, remove the final drive from the subframe -2- toward the rear.

-- If the rear final drive is replaced, the balance weight -arrow- must be rebuilt on the new rear final drive. Refer to OVERVIEW - FINAL DRIVE 0BC, 0BD - BALANCE WEIGHT ON THE REAR FINAL DRIVE .

Fig 12: Identifying Balance Weight

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