Renewing oil seals for side shaft - gearbox with separate oil systems — AUDI

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010), Audi A6 C6 (4F, 2004–2011)

• Special tools named: 27 mm open-end spanner
• Renewed: securing bolt for side shaft, o-ring, oil seal between final drive

Don't miss

• Observe relevant disposal regulations.Some ATF always remains in the oil pan.(Arrow B) can be disregarded.
• Counterhold with hexagon wrench T40124 and 27 mm open-end spanner (item 1).
• Ensure that magnet makes full contact with baffle plate.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Place used oil collection and extraction unitV.A.G 1782 below gearbox.
2. Remove ATF drain plug (arrow A) and allow ATF to drain off. [Note: Observe relevant disposal regulations.Some ATF always remains in the oil pan.(Arrow B) can be disregarded.]
3. Remove drain plug (C) and allow gear oil to drain out of transfer box.
4. Loosen bolts (arrows) for cover for front final drive in diagonal sequence and remove bolts.
5. Catch escaping gear oil using used oil collection and extraction unitV.A.G 1782.

6. Detach cover for front final drive together with differential.
7. Place cover for front final drive together with differential on a soft surface.
8. Lever flange shaft (right-side) off differential (arrows) using two levers.
9. Drive oil seal for flange shaft out of cover for front final drive using a drift.
10. Remove bolts (arrows) and detach baffle plate.
11. Remove flange shaft (left-side) .
12. Remove torque converter.
13. ⚠ The self-locking centre differential can drop out of the gearbox when the centre differential housing is removed. — Loosen bolts (arrows) on housing for centre differential in diagonal sequence and remove bolts.
14. Slowly and carefully pull housing for centre differential off gearbox.
15. Pull self-locking centre differential (arrow) off input shaft.
16. Take off shim (1).
17. Slacken bolts on intermediate flange for front axle drive in the sequence (19 ... 1) and remove bolts.
18. Take off intermediate flange for front axle drive and gasket.
19. Take off intermediate pinion for front axle drive (1) with input shaft.
20. Take off shims (2) and (3).
21. Remove magnet (arrow) from gearbox housing.
22. Remove securing bolt for side shaft using 17 mm socket with approx. 350 mm extension.
23. Counterhold with hexagon wrench T40124 and 27 mm open-end spanner (item 1).
24. Pull out side shaft.
25. Loosen bolts (1 … 18) for torque converter bellhousing in diagonal sequence and remove bolts.
26. Take off torque converter bellhousing and protective tube for side shaft.
27. Remove conical washer (1) from end of pinion shaft (2).
28. Knock an awl (1) into the pinion shaft oil seal and make a small hole (arrow) for fitting a self-tapping screw in the oil seal.
29. Screw self-tapping screw with large head (arrow) into hole in oil seal.
30. Make a notch (arrow) in the centre of a sturdy assembly lever (1) to take up the self-tapping screw.
31. Apply assembly lever to self-tapping screw.
32. ⚠ For protection, insert a suitable piece of wood or plastic (2) between the assembly lever and gearbox housing.Take care not to damage the housing. — Pull out pinion shaft oil seal.
33. Slide fitting tool T40120/2 onto end of pinion shaft.
34. Drive in new pinion shaft oil seal evenly as far as stop using thrust piece T40120/1.
35. Pull out oil seal for side shaft using extractor tool T20143/2.
36. Drive in oil seal for side shaft evenly as far as stop using thrust piece T40121.
37. Renew sealing sleeves (4) and (5).
38. Check that dowel sleeves (1) and (3) are fitted.
39. Insert protective tube (2) for side shaft in gearbox housing.
40. Stick conical washer (1) onto end of pinion shaft (2) using a small amount of grease.
41. Fit torque converter bellhousing on gearbox and tighten bolts (1 … 18) diagonally in stages.
42. Renew securing bolt for side shaft.
43. Insert securing bolt through washer in side shaft and apply 17 mm socket with approx. 350 mm extension to bolt.
44. With socket applied, insert side shaft into gearbox.
45. Counterhold with hexagon wrench T40124 and 27 mm open-end spanner (item 1).
46. Tighten securing bolt for side shaft in five stages as follows:
47. Tighten bolt to 60 Nm. — 60 Nm (44 lb-ft)
48. Slacken bolt.
49. Tighten bolt to 60 Nm once again. — 60 Nm (44 lb-ft)
50. Slacken bolt.
51. Tighten bolt to 77 Nm. — 77 Nm (57 lb-ft)
52. Slide magnet (arrow) into gearbox housing, as shown in illustration.
53. Install intermediate pinion for front axle drive (1) with input shaft.
54. Fit shims (2) and (3).
55. Check that dowel sleeve (1) is fitted.
56. Renew gasket for intermediate flange for front axle drive.
57. Fit intermediate flange for front axle drive on gearbox housing.
58. Tighten bolts on intermediate flange for front axle drive in two stages as follows:
59. Pre-tighten bolts to 5 Nm in sequence (1 ... 4). — 5 Nm (3.7 lb-ft)
60. Tighten bolts to 30 Nm in sequence (1 ... 19). — 30 Nm (22 lb-ft)

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