Final drive/transmission housing oil seal, replacing

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2009 Audi A4, 2008 Audi S4, 2008 Audi A4, 2007 Audi S4, and 2007 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Final Drive/Transmission Housing Oil Seal, Replacing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Drip tray V.A.G 1306
Extractor lever VW 681
Thrust piece T10139

Requirements

Transmission is removed
Transmission mounted on assembly stand → Transmission, securing to assembly stand .

CAUTION: Do not place transmission down on the oil pan.

Procedure

NOTE:

A faulty seal allows gear oil to enter the torque converter bell housing.
General repair instructions → General repair instructions .
Read the rules for cleanliness when working on the automatic transmission → Rules for cleanliness .

Remove transmission support (right-side) → Transmission support and transmission mounting, removing and installing (left and right) .
Place drip tray V.A.G 1306 under transmission.
Remove flange shaft (right-side) → Flanged shaft (right side), removing and installing .

Fig 2: Removing/Installing Bolts On Final Drive Cover In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts on final drive cover in sequence - 11 to 1 - and remove cover together with outer race for tapered roller bearing and shim.

NOTE:

Thickness of shim has been measured to fit; the shim must not be replaced with another shim of different thickness.

Fig 3: Identifying Tapered Roller Bearing Outer Race For Differential And Shim

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove differential.
Remove tapered roller bearing outer race - 1 - for differential and shim - 2 - (behind outer race) from transmission housing by hand.

NOTE:

Thickness of shim has been measured to fit; the shim must not be replaced with another shim of different thickness.

Fig 4: Pulling Out Oil Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove flange shaft (left-side) → Flange shaft (left-side), removing and installing .
Remove seal.

NOTE:

The oil seal extractor lever VW 681 must be applied behind the two sealing lips of the oil seal. Do not apply the lever to the outer circumference of the seal, as this would damage the sealing surface in the transmission. Guide the lever carefully when removing the seal.

Examine oil seal seat in transmission housing for damage; reface surface if necessary.
Lightly lubricate outer circumference and sealing lip of oil seal with gear oil.

NOTE:

Push the seal onto the thrust piece with the protruding sealing lip of the seal facing the tool.

Fig 5: Driving In New Oil Seal As Far As Stop Using Thrust Piece T10139

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive in new oil seal as far as stop using thrust piece T10139.

Fig 6: Identifying Tapered Roller Bearing Outer Race For Differential And Shim

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert shim - 2 - and tapered roller bearing outer race - 1 - for differential onto stop in transmission housing by hand.

NOTE:

Make sure that shim and outer race are kept straight when inserting.

Fig 7: Identifying Cover For Front Final Drive And O-Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace O-ring - arrow -.
Install differential in transmission housing.

Note the following if the outer race for tapered roller bearing and the shim have dropped out of the final drive cover:

Lubricate shim and outer race for tapered roller bearing with gear oil and insert in final drive cover as far as the stop.

Fig 8: Removing/Installing Bolts On Final Drive Cover In Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten bolts of cover for final drive as follows.

Step	Tightening sequence
I	Tighten bolts - 1 - and - 2 - to 3 Nm.
II	Tighten bolts - 1 to 11 - to 23 Nm in the sequence indicated.

Install flange shaft (left-side) → Flange shaft (left-side), removing and installing .
Install flange shaft (right-side) → Flanged shaft (right side), removing and installing .
Install transmission support (right-side) → Transmission support and transmission mounting, removing and installing (left and right) .
Check oil level in front final drive → Front final drive gear oil .