Removing and installing transfer box with Torsen differential — AUDI

🧭 Before you start

Fits: Audi A8 D2 (4D)

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• Before removing propshaft, mark position of constant velocity joint of propshaft in relation to output flange at transfer box to facilitate re-installation.

📋 Procedure

1. Remove front exhaust pipes (left and right) with catalytic converters 26.
2. Remove front exhaust pipe (left-side) with catalytic converter 26.
3. Remove heat shield for propshaft from cover for Torsen differential (arrows). [Note: Before removing propshaft, mark position of constant velocity joint of propshaft in relation to output flange at transfer box to facilitate re-installation.]
4. Detach propshaft from transfer box and place on heat shield.
5. Drain off gear oil from transfer box .

6. Slacken bolts (arrows) on transfer box housing in diagonal sequence and remove bolts.
7. ⚠ Detach transfer box housing from gearbox carefully towards the rear. The Torsen differential may otherwise fall out of the gearbox. — Pull Torsen differential (arrow) off output shaft.
8. Check that dowel sleeves (arrow A) and (arrow B) are fitted in intermediate flange for front axle drive.
9. Apply a thin coating of gear oil to sealing surface (D) (to prevent gasket from slipping) and place gasket in position.
10. Clean magnet and insert it in chamber (1) in intermediate flange for front axle drive.
11. Put 200 ml of gear oil into Torsen differential .
12. Fit Torsen differential (arrow) on splines of output shaft and lowest spur gear, turning it slightly at the same time.
13. Check whether the attached Torsen differential can be turned manually.
14. Position transfer box housing at rear of gearbox with spur gears and output flange fitted.
15. Insert bolts (arrows) on transfer box housing and tighten in diagonal sequence.
16. Secure propshaft to transfer box .
17. Fill transfer box with gear oil and check oil level .

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