Transmission Output Shaft With Splines

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2016 Audi A4 Quattro, 2015 Audi A4 Quattro, 2014 Audi A4 Quattro, 2013 Audi A4, and 2012 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Thrust Plate VW 402
Thrust Disc VW 412
Press Tube 30 - 100
Pulling Hook T20143
Subframe Support Assembling Device T40239
Sealing grease G 052 128 A1

Procedure

-- Remove the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED .

-- Remove the circlip -arrow- on the inside of the housing.

Fig 1: Removing/Installing Circlip On Inner Side Of Cover

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The circlip secures the transmission output shaft to the bearing in the housing.

-- Carefully remove the transmission output shaft from the center differential housing using a copper mandrel.

NOTE:

To remove the transmission output shaft, secure the center differential housing in a vise or have a 2nd technician hold it tight.

-- Pry out the shaft seal -1-.

Fig 2: Prying Out the Shaft Seal -1-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -2-.

Installing

-- Coat the outer edge of the shaft seal with axle oil.

Installed position: The open side of the seal faces the housing.

-- Install the shaft seal using the T40239, -1-. Do not bend the seal.

Fig 3: Install Shaft Seal Using T40239

Courtesy of AUDI OF AMERICA, LLC

-- Fill the space between the sealing and dust lip half way with sealing grease G 052 128 A1.

-- Install the transmission output shaft into the center differential housing as follows:

-- Install the transmission output shaft into the center differential housing from underneath.

-- Position the housing and transmission output shaft on the VW 402 under the shop press.

Fig 4: Installing the Flange Shaft

Courtesy of AUDI OF AMERICA, LLC

-- Mount the 30 - 100 on the ball bearing inner race.

-- Install the transmission output shaft.

-- Install the locking ring -arrow- into the groove on the transmission output shaft.

Fig 5: Removing/Installing Circlip On Inner Side Of Cover

Courtesy of AUDI OF AMERICA, LLC

-- Install the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, TRANSMISSION INSTALLED .

-- Fill gear oil in transfer case. Refer to TRANSFER CASE GEAR OIL, DRAINING AND FILLING .