Shaft seal in front final drive intermediate flange, 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 final drive intermediate flange there is an oil leak inspection opening - arrow - for shaft seal in drive pinion and shaft seal in front final drive intermediate flange.

Work procedure

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

Fig 2: Identifying Drive Shaft Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive shaft seal - arrow - out in toward transfer case using a drift.
Check shaft seal seating in front final drive intermediate flange for damage, rework if necessary.

Fig 3: Slide Shaft Seal Onto Thrust Piece 3404

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide shaft seal onto Thrust Piece 3404.

The larger, projecting outer race - arrow - on shaft seal faces toward thrust piece.

Drive shaft seal in with Thrust Piece 3404 as far as thrust piece stop.
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 .