Renewing gasket between front intermediate housing and gearbox housing — AUDI

Special tools and workshop equipment required

Drift sleeve 30-100
Thrust piece 3334
Hot air blower V.A.G 1416
1 - Puller Kukko 20-10
2 - Arms for puller Kukko 1-250

Removing

Gearbox removed

Remove torque converter.

Secure gearbox to repair stand
=>Page
37-47
Drain ATF=>Page
37-55
.
Unscrew bolt securing drive flange -arrow- (screw 2 bolts into flange and brace with a suitable lever).
Pull out drive flange (if necessary, release with 2 levers).

Note:

Do not damage collar on gearbox housing when levering off drive flange.

Lever out oil seal for propshaft drive flange with a screwdriver.

Notes:

Do not damage seating surfaces for oil seal.
Illustration shows gearbox in vehicle.

Loosen securing bolts -arrows- on cover for transfer gear housing in diagonal sequence and remove bolts.
Remove housing cover.

Note:

When removing housing cover, prevent spur gears from dropping out.

Take out spur gears. When doing this, watch position of tensioning nut -arrow-.
Put down spur gears in bearing shells in housing cover.

Loosen securing bolts -arrow- for transfer gear housing in diagonal sequence and remove.
Pull transfer gear housing off gearbox.

Pull centre differential -arrow- off output shaft towards the rear.

Loosen securing bolts -arrow- for rear intermediate housing in diagonal sequence and remove bolts.

Apply heat to rear intermediate housing -arrows- using hot air blower V.A.G 1416.
Remove housing.

Mark drive pinion -1- and intermediate pinion -2-, to ensure they are installed later in the correct positions and facing the right way.
Lift output shaft bearing approx. 10 mm.

A -
Puller, e.g. Kukko 20-10
B -
Arms for puller, e.g. Kukko 1-250

Take out drive pinion and intermediate pinion.

Loosen securing bolts -arrows- for front intermediate housing in diagonal sequence and remove bolts.
Pull front intermediate housing off gearbox.

Put down front intermediate housing on a clean surface.

Lever out oil seal for transfer gearing with a screwdriver.

Note:

If there is visible scoring on the intermediate shaft, renew intermediate shaft together with oil seals=>Page
39-17
.

Installing

Installation is carried out in the reverse order, when doing this note the following:

Note:

Replace gaskets and seals.

Drive oil seal in onto to stop using thrust piece 3334.

Install drive pinion and intermediate pinion according to markings made earlier.
Drive on output shaft bearing over output shaft.
Apply heat to rear intermediate housing using hot air blower V.A.G 1416 and install housing.
Install centre differential.
Install bolts for transfer gear housing and tighten in diagonal sequence to specified torque in several stages.

Stick tensioning nut for flange shaft -arrow- to front side of spur gear 2.

Note:

Only use Vaseline. Other types of grease will impair the function of the hydraulic gearbox actuators.

Install spur gears 1 and 2.

Install bolts securing cover for transfer gear housing and tighten in diagonal sequence to specified torque in several stages.
Install oil seal for propshaft drive flange and install drive flange=>Page
39-49
.
Fill up withATF => Page
37-55
.

Tightening torques

Component · Nm
Front intermediate housing to gearbox housing · / 23
Rear intermediate housing to front intermediate housing · / 23
Transfer gear housing to rear intermediate housing · / 23
Cover for transfer gear housing to transfer gear housing · / 23
Hexagon socket head bolt for rear flange shaft · / 23