Rear Flange Shaft, Seal And Ball Bearing, Removing And Installing

Special tools and workshop equipment required 

• Press Plate VW401
• Press Plate VW402
• Press Piece - Multiple Use VW412
• Press Piece - 60mm VW415A
• Press Piece - Press Tube 30-100
• Press Piece - Front Control Arm 2040
• Seal Installer - Cardan Flange T40165
• Sealing Grease G 052 128 A1

Procedure 

Fig 1: Identifying Circlip

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-- Remove the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING, BOLTED DRIVESHAFT .

-- Remove the circlip -arrow-.

-- Remove the flange shaft by positioning the center differential housing so the flange shaft does not touch the pressure plates VW401 and VW402.

Fig 2: Pressing Out Flange Shaft

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-- Pry out the shaft seal -1-.

Fig 3: Prying Out Shaft Seal

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-- Remove the flange shaft ball bearing and spacer sleeve if necessary.

Fig 4: Removing Flange Shaft Ball Bearing And Spacer Sleeve

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-- Installing the flange shaft ball bearing.

Fig 5: Installing Transmission Output Shaft Ball Bearing

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• The shoulder on the Press Piece - 60mm VW415A -arrow- faces the Press Piece - Multiple Use VW412.

-- The press in the spacer sleeve -item  5- using the Press Piece - 60mm VW415A. Refer to OVERVIEW - CENTER DIFFERENTIAL HOUSING WITH FLANGE SHAFT (BOLTED DRIVESHAFT), see Figure.

-- Lightly oil the outer circumference on the shaft seal and then install it all the way using the Seal Installer - Cardan Flange T40165.

Fig 6: Cardan Flange T40165 Seal Installer

Courtesy of AUDI OF AMERICA, LLC

• Installation position: the open side of the seal faces the transmission.

-- Fill the space between the sealing and dust lip halfway with Sealing Grease G 052 128 A1.

-- Install the flange shaft.

Fig 7: Identifying Tool Set Up/Assembly

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-- Install the flange shaft into the center differential housing from underneath.

-- Position the housing and flange shaft on the Press Plate VW402 under the shop press.

-- Press in the bearing inner race using the Press Piece - Press Tube 30-100 on the flange shaft.

-- Install a new circlip -arrow- on the flange shaft.

Fig 8: Identifying Circlip

Courtesy of AUDI OF AMERICA, LLC

-- Install the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING, BOLTED DRIVESHAFT - INSTALLING .