Renewing right oil seal for input shaft — AUDI

The following special tools and test units are required for this work:

Kukko 21/5
Multi-purpose tool VW 771
Press piece 3322

Removing

Remove front right wheel.
Remove right front exhaust pipe.

=> 5-cylinder injection engine, (4-valve, Turbo), Mechanics; Repair Group 26; Removing and installing parts of exhaust system
5-cylinder injection engine, (4-valve, Turbo), Mechanics
Removing and installing parts of exhaust system

=> 6-cylinder injection engine (2.6 l engine, 2-valve), Mechanics; Repair Group 26; Removing and installing exhaust system; B - Vehicles with four wheel drive
6-cylinder injection engine (2.6 l engine, 2-valve), Mechanics
Removing and installing exhaust system
B - Vehicles with four wheel drive

=> 6-cylinder injection engine (2-valve), Mechanics; Repair Group 26; Removing and installing exhaust system; C - Vehicles with four wheel drive
6-cylinder injection engine (2-valve), Mechanics
Removing and installing exhaust system
C - Vehicles with four wheel drive

=> 6-cylinder engine (5-valve), Mechanics; Repair Group 26; Removing and installing parts of exhaust system; Vehicles with four wheel drive, engine code ACK
6-cylinder engine (5-valve), Mechanics
Removing and installing parts of exhaust system
Vehicles with four wheel drive, engine code ACK

Disconnect track control arm and guide link from right suspension strut and swing to side.

=> Running Gear 4WD; Repair Group 40; Removing and installing front suspension strut
Running Gear 4WD
Removing and installing front suspension strut

Remove right drive shaft.

=> Running Gear 4WD; Repair Group 40; Removing and installing drive shaft
Running Gear 4WD
Removing and installing drive shaft

Place a drip tray underneath.
Drain gear oil in front final drive=>page
39-4
.

Remove centre bolt -arrow- for right flange shaft by screwing two bolts into flange shaft and bracing with a suitable lever.
Place a drip tray underneath.
Pull out right flange shaft.

Loosen securing bolts -arrow- for differential cover using diagonal sequence and remove bolts.
Remove differential cover.

Notes:

Secure the differential against falling out when removing the differential cover.
Do not interchange the bearing outer races and shims in the differential cover and gearbox housing.

Take out differential with inner race of taper roller bearing.
Remove input shaft=>page
39-26
.

Assemble Kukko 21/5 -A- and multi-purpose tool VW 771 as shown in illustration and pull out oil seal.

Note:

When attaching make sure that the extractor hooks -1- of Kukko 21/5 only contact the oil seal and do not rest on the gearbox housing.

Installing

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

Moisten outer circumference and sealing lips of oil seal with gear oil or coat thinly with Vaseline.
Check oil seal seat in gearbox housing for damage and rework if necessary.
Slide on new oil seal with sealing lip -arrow- facing thrust piece 3322.
Drive on oil seal up to stop.

Insert shim -2- and bearing outer race for differential -1- into housing up to stop by hand. Keep parts straight when installing.

Renew O-ring -arrow- and coat with Vaseline.
Insert shim and bearing outer race into differential cover if they have fallen out.
Insert differential into gearbox housing.

Fit differential cover and tighten securing bolts -arrow- using diagonal sequence.
Fill front final drive of automatic gearbox with gear oil and check oil level=>page
39-4
.

Tightening torques

Component · Nm
Differential cover to gearbox housing · / M8 · / 23
Right flange shaft to gearbox · M8 · 25
Drive shaft to flange shaft · M10 · 77
Drive shaft to wheel hub / collar bolts 1) · / M16 · / 190 + 90°2)
Track control arm to suspension strut 1) · / 55

1)
Renew bolts/nuts

2)
90°is the same as a quarter turn