Final Drive 0BC Removing And Installing, AUDI Q635 Hybrid: Installing

Install in reverse order of removal. Pay attention to the following:

Tightening specifications. Refer to OVERVIEW - FINAL DRIVE 0BC, 0BD .

WARNING:

Handling the high-voltage cables:

Do not stand on or place tools on the high-voltage cables or their components. This may damage the insulation.
Do not bend or kink high-voltage cables as this may damage the insulation.
The round high-voltage connectors are color coded with an exterior colored ring and mechanically coded with guide or code tabs. Observe the coding when connecting the round high-voltage connector in order to avoid mechanical damage to the high-voltage connector.

-- With a second technician, position the rear final drive -1- on the subframe -2- in its installed position.

Fig 1: Mount Rear Final Drive On Subframe

Courtesy of AUDI OF AMERICA, LLC

-- Insert the left drive axle -3- into the final drive flange shaft.

-- The second technician must now push the rear final drive -1- toward the left side of the vehicle in direction of -arrow-.

-- Then install the right drive axle -5- into the final drive flange shaft -4-.

-- Remove the Engine and Gearbox Jack VAS6931 with the Engine/Gearbox Jack Adapter - Wheel Hub Support T10149 from the left rear suspension.

-- Position the Engine and Gearbox Jack VAS6931 and the Universal Transmission Support VAG359/2 and a block of wood (approximately 80 mm tall) under the rear final drive -A-.

Fig 2: Placing VAG 1383 A With VAG 1359/2 And A Block Of Wood

Courtesy of AUDI OF AMERICA, LLC

-- Move the final drive -A- forward slightly.

-- Turn the upper crossmember -B- opposite the direction of -arrow 1- to the left and insert it while guiding it past the final drive -arrow 2-.

-- Tighten the bolts connecting the crossmember -B- to the rear final drive diagonally. Tightening Specification, refer to -item 4- Bolt (See Figure).

Fig 3: Guiding T40154 Through Holes In Subframe -A-

Courtesy of AUDI OF AMERICA, LLC

-- Guide the Socket - Xzn 12 T40154 through the holes in the subframe -A-. Move the final drive to the left or right just a little, if necessary.

-- First tighten the bolts -2 and 4- hand-tight.

Fig 4: Removing Left And Right Driveshaft

Courtesy of AUDI OF AMERICA, LLC

NOTE:

For better illustration the Engine and Gearbox Jack VAS6931 with the Universal Transmission Support VAG359/2 are not shown.

-- Tighten the bolt -4-. Refer to -item 3- Bolt (See Figure).

-- Tighten the bolts -2-. Tightening Specification, refer to -item 2- Bolt (See Figure).

-- Remove the Engine and Gearbox Jack VAS6931 from under the final drive.

-- Tighten the left -1- and right -3- drive axles. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Tighten the potential equalization cable -2- to the rear final drive.

Fig 5: Removing Bolt From Potential Equalization Cable

Courtesy of AUDI OF AMERICA, LLC

Bolt tightening specification -3- on the final drive: 20 Nm

-- Attach the left drive axle heat shield -A- to the crossmember/rear final drive -arrows-. Refer to -item 6- Bolt (See Figure).

Fig 6: Removing Left Driveshaft Head Shield

Courtesy of AUDI OF AMERICA, LLC

-- Attach the driveshaft to the rear final drive. Refer to INSTALLING .

Fig 7: Identifying Driveshaft Intermediate Bearing Mounting Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Attach the driveshaft intermediate bearing to the body free of tension. Tightening Specification. Refer to -item 8- Bolt (See Figure).

-- Check the gear oil level in the rear final drive. Refer to GEAR OIL, CHECKING LEVEL, 0BC .

-- Install the rear section of the exhaust system and align it so it is free of tension. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- Install the left rear wheel and tighten. 140 Nm. .

Energizing the High-Voltage System

Only by using the Guided Fault Finding in the Vehicle Diagnostic Tester can the high-voltage system be restarted.

CAUTION:

Extremely dangerous high-voltage

Severe bodily injury or death by electrocution

The high-voltage system may only be restarted by a qualified person (Audi high-voltage technician).
Only the Vehicle Diagnostic Tester via the "Guided Fault Finding" can guarantee if the voltage has been re-energized.
Qualified personnel (Audi high-voltage technician) restart the vehicle.
The qualified personnel (Audi high-voltage technicians) mark the vehicle with a label.

NOTE:

Energizing the high-voltage system:

Connect the Vehicle Diagnostic Tester

Select the Guided fault finding mode

Using the Go To button, move through the following menu points

Function/component selection

Body

Electrical Equipment

OBD-capable system

8C - hybrid battery management -J840

8C - hybrid battery management, functions

51 - High-voltage re-energizing (Rep.Gr. 93)