Transmission Output Shaft With Splines, Seal And Ball Bearing, Removing And Installing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Press Plate VW401
Press Plate VW402
Press Piece - Multiple Use VW412
Press Piece - Press Tube 30-100
Press Piece - Front Control Arm 2040
Seal Installer - Output Shaft T40238
Sealing Grease G 052 128 A1

Procedure

Fig 1: Identifying Circlip

Courtesy of AUDI OF AMERICA, LLC

-- Remove the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING, ATTACHED DRIVESHAFT .

-- Remove the circlip -arrow A-.

-- Remove the locking ring -arrow B- as well if the ball bearing is also being removed.

Transmission output shaft with splines without vibration damper:

Fig 2: Identifying Dust Ring

Courtesy of AUDI OF AMERICA, LLC

-- Pry off the dust ring -1-.

NOTE:

The dust ring cannot be removed without destroying it.

-- Position the center differential housing so that the transmission output shaft with splines does not touch the thrust plates Press Plate VW401 and Press Plate VW402 and remove the transmission output shaft with splines.

Fig 3: Pressing Out Flange Shaft

Courtesy of AUDI OF AMERICA, LLC

Transmission output shaft with splines and vibration damper:

-- Position the center differential housing so that the vibration damper does not touch the thrust plates Press Plate VW401 and Press Plate VW402 and remove the transmission output shaft with splines.

All:

Fig 4: Prying Out Shaft Seal

Courtesy of AUDI OF AMERICA, LLC

-- Pry out the shaft seal -1-.

NOTE:

Ignore -item 2-.

-- Remove the transmission output shaft ball bearing with splines, if necessary.

Fig 5: Removing Flange Shaft Ball Bearing And Spacer Sleeve

Courtesy of AUDI OF AMERICA, LLC

-- Install the transmission output shaft ball bearing.

Fig 6: Installing Transmission Output Shaft Ball Bearing

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The shoulder on the Press Piece - 60mm VW415A -arrow- faces the Press Piece - Multiple Use VW412.

-- Coat the seal on the outer circumference lightly with oil and then install it all the way in using Seal Installer - Output Shaft T40238.

Fig 7: Installing Output Shaft Seal Into Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

Installation position: the open side of the seal faces the transmission.

-- Fill the space between the sealing and dust lip halfway with Sealing Grease G 052 128 A1.

-- Install the transmission output shaft into the center differential housing as follows:

Fig 8: Identifying Tool Set Up/Assembly

Courtesy of AUDI OF AMERICA, LLC

-- Attach the vibration damper (if equipped) to the center differential housing. Tightening specification. Refer to -item 1- Bolt (See Figure).

-- Install the transmission output shaft with splines into the center differential housing from underneath.

-- Position the housing and transmission output shaft on the Press Plate VW402 under the shop press.

-- Mount the Press Plate 30-100 on the ball bearing inner race.

-- Install the transmission output shaft.

-- Mount the circlip for the transmission output shaft with splines -arrow A- and for the ball bearing -arrow B-.

Fig 9: Identifying Circlip

Courtesy of AUDI OF AMERICA, LLC

Transmission output shaft with splines without vibration damper:

Fig 10: Identifying Dust Ring

Courtesy of AUDI OF AMERICA, LLC

-- Install a new dust ring -1-.

All:

-- Install the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING, ATTACHED DRIVESHAFT - INSTALLING .