Center differential, removing and installing: Installing

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.

Installation is reverse of removal, noting the following:

Fig 1: Location Of Alignment Pins -A/B-, Magnet and Seal Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check for presence of dowel sleeves (arrows - A - and - B - ).
Install gasket

NOTE:

Lightly coat sealing surface -D- with gear oil to prevent the seal from slipping.

Slide cleaned magnets into cast holding pocket - 1 - in intermediate flange.
Add 200 ml. gear oil to output housing (comparable to gear oil, topping up on removed and disassembled center differential).

Fig 2: Pulling Torsen Differential From Output Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install Torsen differential onto splines of output shaft and bottom spur gear while turning slowly.
Check whether installed Torsen differential can be turned by hand.

Fig 3: Transfer Case, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install fully assembled transfer housing with installed spur gears and drive flange/drive shaft onto transmission flange.
Insert bolts - A - and - C - for transfer housing - 2 - and tighten to final tightening torque in diagonal sequence in several stages.
Bolt driveshaft to output flange/driveshaft →
- 39 FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE
- 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR
Install front exhaust system with catalytic converter. →
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Fill transfer housing with gear oil and check oil level → Gear oil in center differential, changing or topping up after repair .