Renewing gasket for housing end cover for rear intermediate drive — AUDI

Notes:

This work can be performed with the gearbox installed by detaching the propshaft from the gearbox and draining the gear oil from the transfer gearbox.
This work can also be performed with the transfer gearbox removed (complete with front intermediate drive and rear intermediate drive). Bolt the transfer gearbox to bracket VW 307 A with two M8 bolts => Page
39-62
and drain gear oil.
For clarity the following work sequence illustrations show a complete gearbox that has been removed. The gear oil need not be drained to do this.

Removing

Secure gearbox to repair stand => Page
37-49
.
Turn rear of gearbox approx. 45° upwards.

Note:

Always hold the rear of the transfer gearbox up, as otherwise oil will run out.

Remove securing bolt -1- by screwing two bolts into flange shaft and bracing with a suitable lever.
Pull flange shaft off to rear.
Remove securing bolts -arrows- of housing end cover.

Press lower spur gear -1- with blunt end of wooden or plastic rod (e.g. screwdriver handle) in direction of arrow towards transfer gearbox and pull off housing end cover -2- evenly towards rear.

Note:

The spur gears must be held continuously in their bearing seats (towards the transfer gearbox). Otherwise the clamping nut (=> -Item
39-90
) to enable the clamping nut to be reinserted in the lower spur gear.

Secure both spur gears against falling out. The illustration shows one of the possibilities for securing the spur gears.

Installing

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

Notes:

The position of the spur gears, their bearings and shims must not be interchanged.
Damaged spur gears may not be reinstalled. In this case, renew the entire intermediate drive.

Coat new gaskets thinly with Vaseline, place on sealing seat surface of housing and secure.
Before assembling intermediate drive, ensure dowel pins -1- are seated properly.

Pull housings together evenly with securing bolts -arrows- and tighten bolts to final tightening torque using diagonal sequence.
Check oil seal for rear flange shaft and renew if necessary
=> Page
39-86
.
Check oil level in transfer gearbox => Page
39-72
.
Renew gasket between propshaft and gearbox flange by pulling off protective foil and sticking onto gearbox flange. Replenish grease for constant velocity joint if necessary.

Tightening torques

Component · Nm
Rear flange shaft to gearbox · 25
Housing end cover to housing for transfer gearbox · / M8 · / 25
Propshaft to gearbox · M8 · 55
Heat shield for propshaft to gearbox · / M8 · / 23