AWD Vehicles

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2024 Audi SQ5, 2024 Audi Q5 e, 2024 Audi Q5, 2023 Audi SQ5, and 2023 Audi Q5 e. However, it is still accessible from the selected car via links, so may be relevant.

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-- Remove the circlip -arrow-.

-- Remove the bearing inner race OVERVIEW - OUTPUT SHAFT, VEHICLES WITHOUT SELF-LOCKING CENTER DIFFERENTIAL or OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL -arrow- using the Two-Arm Puller (Kukko 20/10):VAS 251 001 and Seal Installer - Shaft Seal:T10431/1 .

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Vehicles without self-locking center differential

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-- Install the four bolts (M8 x 30) -2- in the threaded holes marked with "C" from the Extracting Tool - Adapters:T40413/7 -1-.

-- Bolt the Extracting Tool - Adapter:T40413/7 with the Gearbox Assembly Tool:T40213A .

-- Tighten the Gearbox Assembly Tool:T40213A in the vise or on the Gearbox Support:T40206 .

-- Insert the gear set -1- in the Assembly Tool.

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The gear set is secured with the Retaining Strap:T40155 and Engine/Gearbox Support Shackle (2 pc.):10-222A/12 on the Workshop Crane:VAS 6100 .
The bolts from the Extracting Tool - Adapter:T40413/7 -3- must engage in the holes in the gear assembly from the 7th gear -2-.

3 - Extracting Tool - Adapter:T40413/7

4 - Gearbox Assembly Tool:T40213A

5 - Extracting Tool - Adapter:T40413/8

6 - Extracting Tool - Nut:T40213/3

-- Switch the Gearshift Rail/Shift Fork for 4th and 6th Gear -1-, Gearshift Rail/Shift Fork for 5th and 7th Gear -2- and Gearshift Rail/Shift Fork for 1st and 3rd Gear -3- in the -direction of the arrows-.

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-- Warm the bolt -arrow- to approximately 100 °C (212 °F).

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TIP:

The bolt from the output shaft has a very high loosening torque.

-- Remove the bolt -arrow- with the Socket - Xzn 18mm:T10162A -1-.

If when warning the bolt the oil pipe -2- in the output shaft is damaged it must be replaced.

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-- Drive out the oil pipe -2- using the Valve Guide/Clutch Release Push Rod Seal Drift:10-206 -1- from the output shaft in the -direction of the arrow-.

-- Drive in the new oil pipe on the opposite side again.

-- Then shift all gears into the transmission neutral position.

Continuation for all vehicles

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-- Remove the bolt -arrow- and remove the shift forks for 4/6 gear and 5/7 gear together.

-- Remove the input shaft 1 from the gear set.

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CAUTION:

Damage to input shaft 1

When removing the input shaft 1, the 7th gear wheel may already be loosened and can fall.

-- Shift fork the gearshift rail/shift fork for 1st and 3rd gear -1- and gearshift rail/shift fork for 2nd gear and reverse gear -2- upward in the -direction of the arrow-.

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Vehicles with self-locking center differential

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-- Remove the circlip -1- from the outer output shaft -2-.

Screw in the Thrust Piece:T10205/13 in the Hydraulic Cylinder:VAS 6178 .

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Press on the 4th gear 1, vehicles with self-locking center differential

Fig 1: Press on the 4th Gear -1-, Vehicles with Self-Locking Center Differential

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2 - Press Piece - Multiple Use:30-11

3 - Press Piece - 31.5mm:VW418A

4 - Extracting Tool - Screwdriver Bit:T40413/2

5 - Hydraulic Press:VAS 6178

6 - Extracting Tool - Puller:T40413/1

Vehicles without self-locking center differential

Drive Wheel for spur gear unit 1 and drive wheel roller bearing inner race 2.

Fig 2: Drive Wheel for Spur Gear -1- and Drive Wheel Roller Bearing Inner Race -2-

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3 - Press Piece - Multiple Use:VW426

4 - Extracting Tool - Screwdriver Bit:T40413/2

5 - Extracting Tool - Puller:T40413/1

6 - Hydraulic Press:VAS 6178

-- Remove the spacer sleeve OVERVIEW - OUTPUT SHAFT, VEHICLES WITHOUT SELF-LOCKING CENTER DIFFERENTIAL.

Press on the 4th gear 1, vehicles without self-locking center differential

Fig 3: Press on the 4th Gear -1-, vehicles without Self-Locking Center Differential

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2 - Extracting Tool - Screwdriver Bit:T40413/2

3 - Hydraulic Press:VAS 6178

4 - Extracting Tool - Puller:T40413/1

Continuation for all vehicles

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-- Remove the circlip -2- for the drive axle 2 -1-.

Align the drive axle 2 1

Fig 4: Align the Drive Axle 2 -1-

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CAUTION:

Risk of destroying the gears, shaft and bearing bracket.

To press out the input shaft 2, align as follows.
The bevel -arrow- of the drive axle 2 -1- must be located on the side of the intermediate sprocket for the reverse gear -2-.

Press out the drive axle 2 1, vehicles without self-locking center differential

Fig 5: Press Out the Drive Axle 2 -1-, Vehicles without Self-Locking Center Differential

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2 - Bearing Installer - Multiple Use:32-111

3 - Press Piece - Rod:VW407

4 - Bearing Installer - Bearing Press Plate:T10084A

5 - Press Plate:VW401

6 - Press Plate:VW402

To press on the drive axle 2 have a second technician help.
The bearing bracket must be positioned on the Bearing Installer - Bearing Press Plate:T10084A -arrow-.

Press out the drive axle 2 1, vehicles with self-locking center differential

Fig 6: Press Out the Drive Axle 2 -1-, Vehicles with Self-Locking Center Differential

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2 - Press Piece - Multiple Use:40-105

3 - Press Piece - Rod:VW408A

4 - Press Piece - Multiple Use:VW519

5 - Exhaust Pipe Wedge Set:3140A/1

6 - Press Plate:VW402

7 - Press Plate:VW401

8 - Bearing Installer - Bearing Press Plate:T10084A

To press on the drive axle 2 have a second technician help.
The bearing bracket must be positioned on the Bearing Installer - Bearing Press Plate:T10084A -arrow-.

Continuation for all vehicles

Depending on the servicing in the next work procedure:

Input Shaft 2, Disassembling and Assembling. Refer to INPUT SHAFT 2, DISASSEMBLING AND ASSEMBLING .
Input Shaft 1, Disassembling and Assembling. Refer to INPUT SHAFT 1, DISASSEMBLING AND ASSEMBLING .
Output Shaft, Disassembling and Assembling. Refer to OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING .
Vehicles with self-locking center differential: inner output shaft disassembling and assembling. Refer to INNER OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING, ONLY VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL .

Assembling

Insert the input shaft 2 2 in the bearing bracket

Fig 7: Insert the Input Shaft 2 -2- in the Bearing Bracket

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Warm up the output shaft bearing -1- using the Hot Air Blower.
The bevel -arrow- of the output shaft 2 must be located on the side of the intermediate sprocket for the reverse gear -3-.

Press in the input shaft 2 2 in the bearing bracket 3

Fig 8: Press in the input shaft 2 -2- in the Bearing Bracket -3-

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When pressing in the input shaft 2 pay attention to the splines -arrows-.

1 - Press Piece - Multiple Use:VW412

4 - Extracting Tool - Sleeve:T40413/10

-- Determine and insert the thickest circlip -2- that can still be inserted for the drive axle 2 -1-.

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The following circlips are available. Refer to the appropriate Electronic Parts Information for the part number.

Circlip thickness (mm)
2.41	2.49	2.57
2.45	2.53

4th Gear 1, Installing

Fig 9: 4th Gear -1-, Installing

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3 -

Bearing Installer - Differential Bearing:40-21

Warm the 4th gear -1- using the Inductive Heater:VAS 6414 to 120 °C (248 °F).
When pressing on the splines -arrow- pay attention to the 4th gear -1- and the gear assembly for the 4th gear -2-.
Vehicles with self-locking center differential: insert the circlip OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL

Vehicles without self-locking center differential

Drive wheel for spur gear unit 2, pressing on

Fig 10: Drive Wheel for Spur Gear -2-, Pressing on

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3 - Bearing Installer - Differential Bearing:40-21

Position the spacer sleeve -1- beforehand.
Warm the drive wheel for spur gear unit -2- to 120 °C (248 °F) using the Inductive Heater:VAS 6414 .
The groove on the drive wheel of the spur gear unit points to the Bearing Installer - Differential Bearing:40-21 .

Press on the output shaft roller bearing inner race 1

Fig 11: Press on the Output Shaft Roller Bearing Inner Race -1-

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2 - Press Piece - Trailing Arm:2010

Warm the output shaft roller bearing inner race -1- using the Inductive Heater:VAS 6414 to 120 °C (248 °F).
Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - Trailing Arm:2010 -2-.

Continuation for all vehicles

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-- Carefully guide the input shaft 1 into the gear set -arrow-. While doing so, make sure the needle bearings -A and B- are installed correctly.

-- Position the shift forks and secure with the bolt -arrow-.

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The following procedure is only necessary after disassembling the output shaft.

-- Press in the locking sleeve for the gearshift rail/shift fork 1st and 3rd gear -A- and the locking sleeve for the gearshift rail/shift fork 2nd and reverse gear -B-. Refer to Figure.

Fig 12: Press in the New Retaining Sleeves -A, B, C and D-

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Vehicles without self-locking center differential

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-- Install the four bolts (M8 x 30) -2- in the threaded holes marked with "C" from the Extracting Tool - Adapters:T40413/7 -1-.

-- Bolt the Extracting Tool - Adapter:T40413/7 with the Gearbox Assembly Tool:T40213A .

-- Tighten the Gearbox Assembly Tool:T40213A in the vise or on the Gearbox Support:T40206 .

-- Insert the gear set -1- in the Assembly Tool.

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The bolts from the Extracting Tool - Adapter:T40413/7 -3- must engage in the holes in the gear assembly from the 7th gear -2-.

3 - Extracting Tool - Adapter:T40413/7

4 - Gearbox Assembly Tool:T40213A

5 - Extracting Tool - Adapter:T40413/8

6 - Extracting Tool - Nut:T40213/3

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-- Clean the internal threads of the output shaft with a thread tap.

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-- Install the new bolt -arrow- using the Socket - Xzn 18mm:T10162A -1- and tighten.

-- Then shift all gears into the transmission neutral position.

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-- Warm the bearing inner race OVERVIEW - OUTPUT SHAFT, VEHICLES WITHOUT SELF-LOCKING CENTER DIFFERENTIAL or OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL with a Inductive Heater:VAS 6414 and push with the shoulder downward -arrow A- all the way.

-- Install the circlip -arrow-.

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-- Install the oil pan OVERVIEW - GEAR SET, VEHICLES WITHOUT SELF-LOCKING CENTER DIFFERENTIAL.

-- Install the gear set. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .

Tightening Specifications

Refer to OVERVIEW - BEARING BRACKET
Refer to OVERVIEW - OUTPUT SHAFT