Servicing transfer gear — AUDI

01V 01VA
Gearbox installed

Special tools, testers and auxiliary equipment required

Thrust plate VW 401
Press tool VW 412
Thrust plate VW 402
Thrust pad VW 454
Press tool VW 407
Sleeve 30-21

Sleeve 40-20
Thrust pad 3118
Item 3 Separating tool Kukko 17/2

Important:
Do not run the engine or tow the vehicle if the transfer gear is removed or if the gear oil has been drained from the gearbox.
Notes:

Rules for cleanliness when working on the automatic gearbox => Page
37-147
.
General repair instructions => Page
00-34
.

The parts shown in the following illustration can be removed with the gearbox installed.

Hexagon socket-head bolt
- 25 Nm
Flange shaft, rear
Sealing ring
Replacing => Page
39-61
.

Release and tighten bolt - 23 Nm
4 pieces

Housing cover
O-ring
Lubricate with gear oil

Circlip
Grooved ball bearing
For spur gear 1
Pressing off
=> Fig.
39-55
Pressing on
=> Fig.
39-55

for spur gear 1
For rear final drive set
If damaged, always renew together with spur gear 2 -
17
- Replace
To remove and install pull out towards rear together with -
7
- and -
8
- from transfer gear housing

Circlip
Needle bearing
For spur gear 1
Only remove bearing in order to renew
To replace, heat transfer gear housing to approx. 100 °C and drive out needle bearing to rear with drift (Warning: Wear protective gloves)
Drive in up to stop using sleeve 30-21

Release and tighten bolt - 23 Nm
Loosen and tighten in diagonal sequence

Transfer gear housing
Tensioning nut
For rear flange shaft
-
2
-

Needle bearing
For spur gear 2
Only remove bearing in order to renew
Replacing => Page
39-69
.

Circlip
for spur gear 2
For rear final drive set
When damaged, always renew together with spur gear 1 -
9
-
To remove and install, dismantle transfer gear housing => Page
39-57
and pull out together with -
18
,
19
,
23
-

Grooved ball bearing
For spur gear 2
Pressing off
=> Fig.
39-56
Pressing on
=> Fig.
39-56

Circlip
For securing grooved ball bearing -
18
- in transfer gear housing

Washer
For groove ball bearing -Item
18
-
Before installing, clip on alignment plate -
21
-

Alignment plate
Release and tighten bolt -10 Nm
Circlip
To secure grooved ball bearing -
18
- on spur gear 2 -
17
-

Gasket
Replacing => Page
39-57
.

Torsen differential
Renew complete if damaged
Removing and installing=>Page
39-57

Sealing ring
Replacing => Page
39-65
.

Solenoid
Removing and installing=>Page
39-57

Dowel sleeve
2 pieces

Breather
For transfer gear
Cap is fitted on breather
Installation position: Breather must protrude 10 ... 11 mm from housing without cover

Release and tighten bolt - 23 Nm
Observe the tightening sequence =>Page
39-27

Intermediate drive for front axle drive
Gasket
Replacing => Page
39-24
.

Dowel sleeve
Input pinion
For front final drive
Removing and installing=>Page
39-67

Intermediate pinion
For front final drive
Installation position: gear identification faces towards transfer gear

Output pinion
For front final drive
Installation position: gear identification faces towards transfer gear

Sealing ring
Replacing => Page
39-67
.

Fig1
Pressing off grooved ball bearing for spur gear 1

A -
Separating device 22 ... 4.53 in, e.g. Kukko 17/2

Fig2
Pressing on grooved ball bearing for spur gear 1

Fig3
Pressing off grooved ball bearing for spur gear 2

A -
Separating device 22 ... 4.53 in, e.g. Kukko 17/2

Fig4
Pressing on grooved ball bearing for spur gear 2