Removing and installing thrust tube — AUDI

Special tools, testers and auxiliary equipment required

Multi-purpose tool VW 771 and 771/15
Drip tray V.A.G 1306
Universal mount V.A.G 1359/2
Engine/gearbox jack V.A.G 1383 A

Removing

Rear final drive installed

Place drip tray V.A.G 1306 underneath and drain gearbox oil-arrow B-.
Remove exhaust system behind front exhaust pipe:

=> 4-cyl. injection engine, Mechanics; Repair group 26; Removing and installing parts of exhaust system
4-cyl. injection engine, Mechanics
Removing and installing parts of exhaust system

=> 5-cyl. fuel injection engine (2-valve), Mechanics; Repair group 26
5-cyl. fuel injection engine (2-valve), Mechanics

=> 6-cyl. fuel injection engine, Mechanics; Repair group 26
6-cyl. fuel injection engine, Mechanics

Remove heat shield -1- -arrows-.
Remove heat shield next to rear final drive.

Check whether there is a factory marking (paint spot) on propshaft. If there is no mark, make a coloured mark on rear final drive -B- to indicate the position of prop shaft flange -A-.
Unscrew fastening bolts for propshaft flange.

Secure propshaft to handbrake cable bracket with wire.

Note:

If it is not possible to push propshaft up and off flange, lower final drive before tying up propshaft. When lowering final drive, prevent propshaft from dropping down, and do not bend centre joint further than maximum angle permitted => notes on Page
39-75
.

Support final drive with gearbox lifter V.A.G 1383 A.
Unscrew bolts -arrows- from front of cross member for rear final drive.
Detach front cross member.

Unclip electrical wiring and hoses for differential lock actuator at clips -arrows-.
Lower final drive about 10 cm.
Remove 4 bolts for thrust tube -1 ... 3-

Note:

Fourth bolt is not visible in illustration.

Pull off flange shaft with thrust tube.

Installing

Install in reverse order, paying attention to the following:

Notes:

It is essential that locking fluid remaining in the threads in the flange shafts on the gearbox and rear final drive is cleaned out after removing propshaft. Otherwise there is a danger that new bolts will seize when they are screwed in and then shear if they have to removed later.
Threaded holes can be cleaned with a thread tap.
Replace gasket between prop shaft and drive flange (remove protective sheet and bond gasket to flanged shaft). The adhesive surface must be free of grease.
Replace prop shaft bolts (self-locking).

If there is a factory marking on propshaft, measure radial run-out at flange on final drive=>Page
39-84
and bring marking on propshaft into alignment with new marking on flange.

Align exhaust system free of stress

=> 4-cyl. fuel injection engine, Mechanics; Repair group 26
4-cyl. fuel injection engine, Mechanics

=> 5-cyl. fuel injection engine (2-valve), Mechanics; Repair group 26
5-cyl. fuel injection engine (2-valve), Mechanics

=> 6-cyl. fuel injection engine, Mechanics; Repair group 26
6-cyl. fuel injection engine, Mechanics

Top-up gear oil in rear final drive and check oil level => Page
39-92
.

Tightening torques

Component · Nm
Thrust tube to rear final drive · 35
Propshaft to final drive / (input flange) M8 · 55
Front cross member for rear final drive to body M10 · 40
Front cross member for rear final drive with exhaust system bracket to body M8 · 23
Clamp for exhaust pipe · 40