Removing and installing transfer box with centre differential — AUDI

🧭 Before you start

Fits: Audi A6 C5 (4B)

• Opens: gearbox oil

Don't miss

• Do not run the engine or tow the vehicle if the transfer box is removed or if the gear oil has been drained. — Remove heat shield for propshaft from cover for centre differential (arrows).
• Apply a thin coating of gear oil to sealing surface (D) to prevent gasket from slipping.

📋 Procedure

1. Remove front exhaust pipes 26.
2. ⚠ Do not run the engine or tow the vehicle if the transfer box is removed or if the gear oil has been drained. — Remove heat shield for propshaft from cover for centre differential (arrows).
3. Unbolt propshaft (1) from gearbox and rest it on heat shield (2)Removing and installing propshaft.
4. Secure propshaft with wire (arrow) on bracket (3) for fuel pipes, or support propshaft with engine and gearbox jackV.A.G 1383 A.
5. Drain gear oil from transfer box .

6. Loosen securing bolts (arrows) for transfer box housing in diagonal sequence and remove bolts.
7. ⚠ Detach transfer box housing from gearbox carefully towards the rear. Take care that centre differential does not drop out of gearbox. — Pull centre differential (arrow) off output shaft towards the rear.
8. Check that dowel sleeves (arrow A) and (arrow B) are fitted.
9. Install gasket. [Note: Apply a thin coating of gear oil to sealing surface (D) to prevent gasket from slipping.]
10. Clean the magnet and insert it in chamber (1) on the casting of the intermediate flange.
11. Put 200 ml of gear oil into output cup (filling up with gear oil after transfer box has been removed and dismantled ).
12. Fit centre differential (arrow) onto splines of output shaft and lowest spur gear, turning it slightly at the same time.
13. Check whether centre differential can be turned by hand after being fitted.
14. Fit transfer box housing (with spur gears and rear output flange installed) onto gearbox flange.
15. Insert bolts for transfer box housing and tighten to final torque in diagonal sequence and in several stages.
16. Secure propshaft to gearbox flange Removing and installing propshaft.
17. Fill transfer box with gear oil and check oil level .

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