Transmission Output Shaft, Removing And Installing

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Special tools and workshop equipment required

Press Plate VW402
Press Piece - Multiple Use VW412
Press Piece - Press Tube 30-100
Puller - Crankshaft/Power Steering Seal T20143
Seal Installer - Output Shaft T40239
Sealing Grease G 052 128 A1

Procedure

-- Remove the center differential housing, refer to CENTER DIFFERENTIAL, REMOVING AND INSTALLING .

Fig 1: Removing/Installing Locking Ring At Transmission Output Shaft

Courtesy of AUDI OF AMERICA, LLC

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

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 vice or have a second technician hold it tight.

-- Pry out the shaft seal -1-.

Fig 2: Prying Out Shaft Seal

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore item -2-.

Installing

Fig 3: Installing Shaft Seal Using T40239

Courtesy of AUDI OF AMERICA, LLC

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

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

-- Drive in shaft seal with Seal Installer - Output Shaft T40239, -1- until it stops. Do not tilt the shaft seal during this procedure.

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

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

Fig 4: Identifying Tool Set Up/Assembly

Courtesy of AUDI OF AMERICA, LLC

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

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

-- Mount the Press Piece - Press Tube 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 Locking Ring At Transmission Output Shaft

Courtesy of AUDI OF AMERICA, LLC

-- Install the center differential housing, refer to CENTER DIFFERENTIAL, REMOVING AND INSTALLING .

-- Fill gear oil in transfer case, refer to GEAR OIL, DRAINING AND FILLING .