General Repair Information: Components

Transmission

Make sure that the alignment sleeves between the transfer case and transmission are positioned correctly when installing the transfer case.
Clean the contact surfaces when installing the brackets as well as any waxed components. Contact surfaces must be free of grease and wax.
For the correct bolts and other components, refer to parts
When replacing a transfer case, the gear oil must be filled up to lower edge of filler hole. Refer to TRANSFER CASE, CHECKING TRANSMISSION FLUID LEVEL .
Capacities and specification in the transfer case. Refer to TRANSFER CASE DESIGNATION 0BU
When replacing a front final drive, the gear oil must be filled up to lower edge of filler hole. Refer to AXLE OIL LEVEL IN FRONT FINAL DRIVE, CHECKING .
Capacities and Specifications, Front Final Drive. Refer to CODE, TRANSMISSION ALLOCATION, RATIOS AND CAPACITIES .
When replacing a rear final drive, the gear oil must be filled up to lower edge of filler hole. Refer to REAR FINAL DRIVE AXLE OIL LEVEL, CHECKING .
Capacities and Specifications, Rear Final Drive. Refer to REAR FINAL DRIVE DESIGNATION 0BN AND 0BP .

Sealant

Thoroughly clean housing joint surfaces before applying the Sealant AMV 174 004 01.
Apply the Sealant AMV 174 004 01 evenly and not too thick.

O-Rings, Shaft Seals, Sealing Rings and Seals

Replace the O-rings.
The open side of the shaft seals point toward the fluid to be sealed in.
When installing the new shaft seals, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.

Shaft Seals

Fig 1: Identifying Oil Seal Sealing Lips

Courtesy of AUDI OF AMERICA, LLC

Prior to Installing:

Lightly coat the outer circumference with oil and then fill the space between the sealing lips -arrow- halfway with Sealing Grease G 052 128 A1.

After Installing:

Check the transmission fluid level in the transfer case. Refer to TRANSFER CASE, CHECKING TRANSMISSION FLUID LEVEL .
Check transmission fluid level in front final drive. Refer to AXLE OIL LEVEL IN FRONT FINAL DRIVE, CHECKING .
Check transmission fluid level in the rear final drive. Refer to REAR FINAL DRIVE AXLE OIL LEVEL, CHECKING .

Fasteners

Bolts and Nuts

Tighten and loosen the bolts and nuts for securing covers and housings in a diagonal sequence.
The tightening specifications stated apply to non-oiled nuts and bolts.
Always replace self-locking nuts and bolts.
Make sure the contact surfaces and visible surfaces on the nuts and bolts are waxed after assembling.
Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Next, use Locking Fluid AMV 185 101 A1 to install the bolts.
Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed. Pay attention to the thread pitch when cleaning with a thread cutter.

Bearings

Install needle bearings with lettered side (thicker metal) racing the fitting tool.