INPUT SHAFT SEAL, REPLACING, 0D3 "quattro sport": Installing

WARNING: This page is about a different car, the 2024 Audi S6 and 2024 Audi A6 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

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

Courtesy of AUDI OF AMERICA, LLC

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 .

-- 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-.

-- Install the shaft seal all the way. Be careful not to bend it.

Fig 2: Identifying Shaft Oil Seal Installer T40222

Courtesy of AUDI OF AMERICA, LLC

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

Fig 3: Locating Mark Position Of Flange/Driveshaft To Pinion

Courtesy of AUDI OF AMERICA, LLC

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 .

-- 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 4: Identifying T10380

Courtesy of AUDI OF AMERICA, LLC

Fig 5: Identifying Locking Ring, Installation

Courtesy of AUDI OF AMERICA, LLC

Install the circlip as follows:

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.

-- Measure the thickness of the old circlip -1-.

-- Install a new circlip -1- having the same thickness as the old one. Refer to the Parts Information.

-- Install the new circlip -1-.

A new circlip -arrow- must be selected when replacing the flange/driveshaft.
For this, determine and insert the thickest circlip -arrow- that can still be installed in the groove. Refer to the Parts Information for the part number.

-- Fill the rear final drive gear oil 0D3. Refer to GEAR OIL, FILLING, 0D3 "quattro sport" .

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

-- Install the rear section of the exhaust system. Refer to OVERVIEW - MUFFLER (EA 888EV04) , or OVERVIEW - MUFFLER (EA 839) .