Shaft seal in drive pinion, replacing

WARNING: This page is about a different car, the 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Oil Leak Inspection Opening For Shaft Seal In Drive Pinion And Shaft Seal In Intermediate Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

On the left side of the intermediate shaft, there is an oil leak inspection opening - arrow - for shaft seal in drive pinion and shaft seal in intermediate flange.

Fig 2: Identifying Intermediate Flange For Front Final Drive Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Work procedure

Remove transfer case → 39 - FINAL DRIVE, DIFFERENTIAL .
Remove front final drive intermediate flange → 39 - FINAL DRIVE, DIFFERENTIAL .

CAUTION:

Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the same position to maintain running direction.

Fig 3: Identifying Intermediate Pinion, Drive Pinion, And Pinion Gears, and Input Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark installation position of intermediate pinion - 1 - and pinion gear - 3 -.
Remove pinion gear together with intermediate pinion, while doing so pull drive pinion - 2 - slightly toward rear.
Remove drive pinion - 2 -.
Drive out shaft seal with a drift.

Fig 4: Installing Driveshaft Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide shaft seal onto Thrust Piece 3403.
Drive shaft seal in with Thrust Piece 3403 as far as thrust piece stop.

NOTE:

Ignore - A - and - B -.

Fig 5: Identifying Input Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Completely cover splines on input shaft - arrow - with insulating tape without creasing or overlapping the tape to prevent damage to gasket when sliding on drive pinion.
Install front final drive intermediate flange → 39 - FINAL DRIVE, DIFFERENTIAL .
Install transfer case → 39 - FINAL DRIVE, DIFFERENTIAL .
Check and correct ATF level in planetary gearing → 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .