INPUT SHAFT SEAL, REPLACING, 0DB, 0D2, 0G2, 09R "quattro ultra", 0B0 "quattro ultra": Installing

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Fig 1: Identifying New Seal -A- On T40222/1

Courtesy of AUDI

Install in reverse order of removal. Note the following:

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

-- Place the new shaft seal -A- on the Guide Sleeve:T40222/1 .

Tip:

Make sure the shaft seal spring is in its installation position behind the sealing lip.

-- Coat outer edge of the seal with gear oil.

-- Push the Guide Sleeve:T40222/1 with the shaft seal -A- onto the pinion -B-.

-- Push in the new shaft seal to the >>installation dimension<< using the Seal Installer - Input Shaft:T40222 .

Courtesy of AUDI

Installed dimension

Final Drive	Installed dimension in [mm] under the housing edge
0DB	25.5 ± 0.2
0B0 "quattro ultra"	25.5 ± 0.2
0D2	24.0 ± 0.2
0G2	24.0 ± 0.2
09R "quattro ultra"	24.0 ± 0.2

-- Remove the Seal Installer - Input Shaft:T40222 and Guide Sleeve:T40222/1 .

CAUTION:

Hot components.

Burning of hands is possible.

- Wear safety gloves.

- If using a Heating Plate the temperature must be observed using a Digital Thermometer:VAS 6519 .

-- Warm up the flange/driveshaft -B- with an Inductive Heater:VAS 6414 or a Heating Plate to 115 °C (239 °F).

Fig 2: Locating Mark Position Of Flange/Driveshaft To Pinion

Courtesy of AUDI

-- Position the flange/driveshaft -B- on the pinion -A- so that the mark -arrow- is in a straight line.

-- Install the flange/driveshaft using the Seal Installer - Hollow Shaft:T10380 until it stops.

Fig 3: Identifying T10380

Courtesy of AUDI

Install the circlip -1- as follows:

Fig 4: Identifying Locking Ring, Installation

Courtesy of AUDI

Always replace the circlip -1-.
The bevel on the inner diameter of the circlip -arrow A- faces out, toward the driveshaft.
The wide tab on the circlip -arrow B- must be on the right side, as shown.

Note the following when replacing the flange/driveshaft:

The circlip -1- must be redetermined.
For this, determine and insert the thickest locking ring -1- that can still be installed in the groove. Refer to the appropriate Electronic Parts Information for the part number.

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

Fig 5: Install the driveshaft on the rear final drive.

Courtesy of AUDI

-- Fill the axle oil in the rear final drive and check the level. Refer to GEAR OIL, CHECKING LEVEL .

-- Install the crossmember. Refer to OVERVIEW - UNDERBODY BRACING .

-- Assemble the exhaust system. Refer to OVERVIEW - MUFFLER - 2.0L , OVERVIEW - MUFFLER - 3.0L .