Inner Output Shaft, Disassembling And Assembling, Only Vehicles With Self-Locking Center Differential

Special tools and workshop equipment required 

• Locking Pin Driver: 30-505 
• Bearing Installer - Multiple Use: 40-20 
• Press Plate: VW402 
• Press Piece - Multiple Use: VW412 
• Press Piece - Multiple Use: VW473 
• Bearing Installer - Wheel Bearing: 3345 
• Valve Guide/Clutch Release Push Rod Seal Drift: 10-206 
• Piston Pin Drift: VW207 
• Socket - Xzn 18mm: T10162A 
• Gearbox Assembly Tool: T40213A 
• Extracting Tool - Adapter: T40413/7 
• Extracting Tool - Pin: T40413/9 

• inner output shaft, removing. Refer to Inner Output Shaft Roller Bearing, Removing, Vehicles with Self-Locking Center Differential .

Disassembling

Courtesy of AUDI OF AMERICA, LLC

-- Depending on the diameter -a- Install the three Extracting Tool - Pin: T40413/9  -3- in the Extracting Tool - Adapter: T40413/7  -2- in the hole in the gear for the inner output shaft -1-.

• Dimension -a- = 62 mm threaded holes -A-
• Dimension -a- = 64 mm threaded holes -B-

-- 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  .

-- Position the inner output shaft -1- on the Extracting Tool - Adapter: T40413/7  -3-.

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove the bolt -arrow- with the Socket - Xzn 18mm: T10162A  -2- from the inner output shaft -1-.

Tip:

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

If when warning the bolt the oil pipe -3- in the inner output shaft is damaged it must be replaced.

Courtesy of AUDI OF AMERICA, LLC

-- Drive out the oil pipe -3- using the Valve Guide/Clutch Release Push Rod Seal Drift: 10-206  -2- and Piston Pin Drift: VW207  -1- in direction of -arrow- out of the inner output shaft.

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

Inner Output Shaft 1, Pressing Out

Fig 1: Inner Output Shaft -1-, Pressing Out

Courtesy of AUDI OF AMERICA, LLC

2 -

Press Piece - Multiple Use: VW412 

3 -

Locking Pin Driver: 30-505 

4 -

Press Plate: VW402 

• All additional components remaining on the Press Plate: VW402  must be secured from falling.

-- When removing the components in the sequence, at the same time pay attention to the installation position. Refer to OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL .

Roller Bearing 1 from the Bearing Shell 2, Pressing Out

Fig 2: Roller Bearing -1- from the Bearing Shell -2-, Pressing Out

Courtesy of AUDI OF AMERICA, LLC

3 -

Press Piece - Multiple Use: VW473 

4 -

Bearing Installer - Wheel Bearing: 3345 

5 -

Press Plate: VW402 

• Remove the locking ring -item 4-  OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL => List Item: Circlip beforehand.

Assembling 

Drive Wheel for Spur Gear 1, Pressing On

Fig 3: Drive Wheel for Spur Gear -1-, Pressing On

Courtesy of AUDI OF AMERICA, LLC

2 -

Press Plate: VW402 

3 -

Bearing Installer - Multiple Use: 40-20 

• Installation position: the groove -arrow- from the drive wheel for spur gear -1- points to the Bearing Installer - Multiple Use: 40-20  .

Ball Bearing 1, Pressing On

Fig 4: Ball Bearing -1-, Pressing On

Courtesy of AUDI OF AMERICA, LLC

3 -

Press Plate: VW402 

4 -

Bearing Installer - Multiple Use: 40-20 

• Installation position: the shoulder -arrow- points to the drive wheel for spur gear -2-.

-- Depending on the diameter -a- Install the three Extracting Tool - Pin: T40413/9  -3- in the Extracting Tool - Adapter: T40413/7  -2- in the hole in the gear for the inner output shaft -1-.

Courtesy of AUDI OF AMERICA, LLC

• Dimension -a- = 62 mm threaded holes -A-
• Dimension -a- = 64 mm threaded holes -B-

-- 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  .

-- Position the inner output shaft -1- on the Extracting Tool - Adapter: T40413/7  -3-.

Courtesy of AUDI OF AMERICA, LLC

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

-- Install the new bolt -arrow- using the Socket - Xzn 18mm: T10162A  -2- and tighten.

Roller bearing 1 in the Bearing Shell 2, Pressing in

Fig 5: Roller bearing -1- in the Bearing Shell -2-, Pressing in

Courtesy of AUDI OF AMERICA, LLC

3 -

Press Piece - Multiple Use: VW473 

4 -

Bearing Installer - Wheel Bearing: 3345 

5 -

Press Plate: VW402 

• Position the roller bearing -1- with the lettered side (larger panel thickness) to the Press Piece - Multiple Use: VW473  -3-.

-- Install the circlip -item 4-  OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL => List Item: Circlip.

Tightening Specifications 

• Refer to OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL