Service

Rear final drive 0BC, 0BD, 0BE, 0BF

Edition 06.2015

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
39 - Final drive - rear differential

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

A005A502720
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification of final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Allocation of gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Safety precautions when working on high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Safety precautions and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.3 Jacking mode (vehicles with air suspension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.5 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.1 Exploded view - propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Detaching and attaching propshaft at gearbox or at rear final drive . . . . . . . . . . . . . . . . . . 37
1.4 Renewing protective boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Exploded view - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Removing and installing final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Dismantling and assembling final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.1 Exploded view - dismantling and assembling final drive . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.2 Removing and installing hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3 Dismantling and assembling hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.4 Removing and installing all-wheel drive pump V415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.5 Removing and installing oil pressure and oil temperature sender G437 or oil pressure and oil
temperature sender 2 G640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.6 Removing and installing clutch valve for all-wheel drive N445 or clutch valve 2 for all-wheel
drive N446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.7 Checking torque distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.1 Overview - drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.1 Overview - drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.2 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.3 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.1 Overview of fitting locations - oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.2 Renewing oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3 Renewing oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.4 Renewing input shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.5 Renewing protective ring on flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Contents i
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

6.6 Renewing protective ring on input shaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

7 Renewing propshaft flange, 0BD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8 Gearbox control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.1 Overview of fitting locations - gearbox control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.2 Removing and installing all-wheel drive control unit J492 . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.3 Additional work required after renewing all-wheel drive control unit J492 . . . . . . . . . . . . . . 173

ii Contents
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

00 – Technical data
1 Identification
(ARL004325; Edition 06.2015)
⇒ “1.1 Identification of final drive”, page 1

1.1 Identification of final drive

⇒ “1.1.1 Identification of final drive 0BC”, page 1
⇒ “1.1.2 Identification of final drive 0BD”, page 2
⇒ “1.1.3 Identification of final drive 0BE, 0BF”, page 3

1.1.1 Identification of final drive 0BC

The rear final drive 0BC is installed in conjunction with the fol‐
lowing gearbox types:
♦ 6-speed manual gearbox 0B2, four-wheel drive
♦ 6-speed manual gearbox 0B4, four-wheel drive
♦ 7-speed dual clutch gearbox 0B5, four-wheel drive
♦ Automatic gearbox 0B6, four-wheel drive
♦ 8-speed automatic gearbox 0BK, four-wheel drive
♦ 8-speed automatic gearbox 0BW, four-wheel drive (Q5 hybrid
only)
Rear final drive allocation
♦ ⇒ “2.1 Allocation of gearbox to engine”, page 5
Location on rear final drive
Final drive 0BC -arrow 1- and 0AR
Code letters and date of manufacture -arrow 2-

Final drive 0BC -arrow- and 0AR

1. Identification 1
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Note

♦ The designation “0AR” always appears on the rear final drive

housing. The distinguishing features for final drives “0BC” and
“0AR” are housing modifications.
♦ An additional distinguishing feature is the position of the tap‐
ped holes -arrows- used to secure the cross member to the
rear final drive.
♦ On the final drive unit “0BC” there are 4 tapped holes
-arrows- in the final drive housing for securing the cross mem‐
ber. There is also an additional tapped hole below the prop‐
shaft flange, for securing the final drive to the subframe.

Code letters and date of manufacture for rear final drive

Example: JKS 15 03 07
I I I I
Code letters Day Month Year -2007-
of manufacture
Other information can be disregarded.

Note

When installing a new rear final drive unit, it is important to verify

not only the code letters but also the PR No. and the engine code
of the vehicle in the ⇒ Electronic parts catalogue . This is nec‐
essary to ensure that the correct version is installed.

1.1.2 Identification of final drive 0BD

The rear final drive 0BD is installed in conjunction with the fol‐
lowing gearbox types:
♦ 6-speed manual gearbox 0B2, four-wheel drive
♦ 6-speed manual gearbox 0B4, four-wheel drive
♦ 7-speed dual clutch gearbox 0B5, four-wheel drive
♦ Automatic gearbox 0B6, four-wheel drive
♦ 8-speed automatic gearbox 0BK, four-wheel drive
Rear final drive allocation
♦ ⇒ “2.1 Allocation of gearbox to engine”, page 5
Location on rear final drive
Final drive 0BD, code letters and date of manufacture -arrow-

2 Rep. gr.00 - Technical data

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

-Arrow A- Final drive 0BD with Part No. (in this

example 0BD 500 043A)
-Arrow B- Code letters “JTN”
-Arrow C- Manufacturing data of rear final drive
Exam‐ F 292 3242
ple:
I I I
Year of manu‐ Day of manufac‐ Serial number on
facture -2006- ture day of manufacture
F = 2006, -292nd day of year-
G = 2007, (always specified
H = 2008 ... in three digits)
Other information can be disregarded.

Note

When installing a new rear final drive unit, it is important to verify

not only the code letters of the rear final drive but also the PR No.
and the engine code of the vehicle in the ⇒ Electronic parts cata‐
logue . This is necessary to ensure that the correct version is
installed.

1.1.3 Identification of final drive 0BE, 0BF

The »rear final drive 0BF« is installed in the Audi A4 2008 ►, Audi
A5 Coupé 2008 ►, Audi A5 Cabriolet 2009 ►, Audi A6 2011 ►,
Audi A7 2011 ► and Audi A8 2010 ►.
It is employed in conjunction with the following gearbox types:
♦ 6-speed manual gearbox 0B2, four-wheel drive
♦ 6-speed manual gearbox 0B4, four-wheel drive
♦ 7-speed dual clutch gearbox 0B5, four-wheel drive
♦ Automatic gearbox 0B6, four-wheel drive
♦ 8-speed automatic gearbox 0BK, four-wheel drive
The »rear final drive 0BE« is an uprated version of the »0BF« unit
and is installed exclusively with the V8 TDI engine in the
Audi A8 2010 ►.
It is employed in conjunction with the following gearbox:
♦ 8-speed automatic gearbox 0BL, four-wheel drive
Rear final drive allocation
♦ ⇒ “2.1 Allocation of gearbox to engine”, page 5
Location on rear final drive
Classification of clutches -arrow 1-
Code letters and date of manufacture -arrow 2-

Note

The rear final drive units 0BF and 0BE can be identified by the
hydraulic control unit with superposition gears at the sides.

1. Identification 3
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ -Arrow 1- Code letters -LFW-

♦ -Arrow 2- Manufacturing data of rear final drive
Exam‐ 08 12 09
ple:
I I I
Year -2008- Month Day
of manufacture
♦ -Arrow 3- Classification of clutch on right side (classification of
friction coefficients for clutch). Example: -272D-
♦ -Arrow 4- Classification of clutch on left side (classification of
friction coefficients for clutch). Example: -4A10-
Other information can be disregarded.

Note

When installing a new rear final drive unit, it is important to verify

not only the code letters of the final drive but also the PR No. and
the engine code of the vehicle in the ⇒ Electronic parts catalogue .
This is necessary to ensure that the correct version is installed.

4 Rep. gr.00 - Technical data

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

2 Technical data
⇒ “2.1 Allocation of gearbox to engine”, page 5
⇒ “2.2 Capacities”, page 5

2.1 Allocation of gearbox to engine

The following data can be found in the ⇒ Electronic parts cata‐
logue .
♦ Code letters
♦ Production dates
♦ Axle ratio
♦ Allocation of drive shaft flanges
♦ Allocation to engine and manual or automatic gearbox ac‐
cording to code letters and PR numbers

2.2 Capacities
⇒ “2.2.1 Capacities - rear final drive 0BC”, page 5
⇒ “2.2.2 Capacities - rear final drive 0BD”, page 5
⇒ “2.2.3 Capacities - rear final drive 0BF”, page 5
⇒ “2.2.4 Capacities - rear final drive 0BE”, page 6

2.2.1 Capacities - rear final drive 0BC

Rear final drive 0BC
Capacity 0.9 ltr.
♦ Gear oil specifications ⇒ Electronic parts catalogue

– Check gear oil level ⇒ page 107 .

2.2.2 Capacities - rear final drive 0BD

Rear final drive 0BC
Capacity 0.9 ltr.
♦ Gear oil specifications ⇒ Electronic parts catalogue

– Check gear oil level ⇒ page 107 .

2.2.3 Capacities - rear final drive 0BF

Caution

Gear oil and ATF change

• On some RS models, the gear oil and the ATF must be
changed.
• For change interval, refer to ⇒ Maintenance tables .
• For all other vehicles no change is required.

2. Technical data 5
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Rear final 0BF

drive
Gear oil capacity 0.95 ltr.
♦ For final drive (dif‐
ferential and pinion
shaft)
♦ No change required,
except for RS mod‐
els
♦ Change interval for
RS models ⇒ Main‐
tenance tables
♦ ⇒ “4.2 Checking
gear oil level”,
page 107
♦ ⇒ “4.3 Draining and
filling gear oil”, page
109

Gear oil specification ⇒ Electronic parts catalogue

ATF capacity approx. 0.85 litres
♦ For hydraulic control
unit and superposi‐
tion gears
♦ No change required,
except for RS mod‐
els
♦ Change interval for
RS models ⇒ Main‐
tenance tables
♦ ⇒ “5.2 Checking
ATF level”,
page 116
♦ ⇒ “5.3 Draining and
filling ATF”,
page 117

ATF specification ⇒ Electronic parts catalogue

2.2.4 Capacities - rear final drive 0BE

Note

The rear final drive 0BE is only installed in conjunction with the
V8 TDI engine.

6 Rep. gr.00 - Technical data

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Rear final 0BE

drive
Gear oil capacity 1.4 ltr.
♦ For final drive (dif‐
ferential and pinion
shaft)
♦ No change required,
except for RS mod‐
els
♦ Change interval for
RS models ⇒ Main‐
tenance tables
♦ ⇒ “4.2 Checking
gear oil level”,
page 107

Gear oil specification ⇒ Electronic parts catalogue

ATF capacity 1.4 ltr.
♦ For hydraulic control
unit and superposi‐
tion gears
♦ No change required,
except for RS mod‐
els
♦ Change interval for
RS models ⇒ Main‐
tenance tables
♦ ⇒ “5.2 Checking
ATF level”,
page 116

ATF specification ⇒ Electronic parts catalogue

2. Technical data 7
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

3 Transmission layout

1 - Gearbox
2 - Propshaft
❑ Exploded view
⇒ page 19
❑ Removing and installing
⇒ page 24
3 - Rear final drive
❑ Removing and installing
⇒ page 45
❑ Dismantling and assem‐
bling ⇒ page 90

8 Rep. gr.00 - Technical data

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

4 Electrical components
⇒ “4.1 Overview of fitting locations - electrical components”, page
9

4.1 Overview of fitting locations - electrical components

1 - All-wheel drive control unit

- J492-
❑ Fitting location in A4 sa‐
loon, A5 Coupé and A5
Cabriolet ⇒ page 171
❑ Fitting location in A4
Avant ⇒ page 171
❑ Fitting location in A5
Sportback ⇒ page 172
❑ Fitting location in A6 and
A7 ⇒ page 172
❑ Fitting location in A8
⇒ page 172
❑ Removing and installing
⇒ page 172
❑ Additional work required
after renewing control
unit ⇒ page 173
❑ Important signals are
transferred from the en‐
gine control unit and
ABS control unit - J104-
via data bus to the all-
wheel drive control unit
2 - ABS control unit - J104-
❑ Fitting location; remov‐
ing and installing ⇒
Brake system; Rep. gr.
45 ; Overview of fitting
locations
3 - Diagnostic connection
❑ Fitting location: in driv‐
er's footwell (front)
⇒ page 171
❑ Connecting vehicle di‐
agnostic tester and selecting functions
4 - Hydraulic control unit
❑ Fitting location: on rear final drive
❑ Removing and installing ⇒ page 93
❑ Dismantling and assembling ⇒ page 96
❑ Hydraulic control unit with:
♦ All-wheel drive pump - V415- ⇒ page 99
♦ Oil pressure and oil temperature sender 2 - G640- ⇒ page 101
♦ Oil pressure and oil temperature sender - G437- ⇒ page 101
♦ Clutch valve 2 for all-wheel drive - N446- ⇒ page 104
♦ Clutch valve for all-wheel drive - N445- ⇒ page 104
5 - Instrument cluster display

4. Electrical components 9
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

5 Safety precautions
⇒ “5.1 General safety precautions”, page 10
⇒ “5.2 Safety precautions when working on high-voltage vehi‐
cles”, page 11

5.1 General safety precautions

Observe the following precautions to avoid possible injury and/or
damage to the vehicle:

WARNING

Accidents and injury can be caused if a gear is inadvertently

engaged while the engine is running.
♦ Before performing any work with the engine running, set
the gearbox to position “P” and pull up the parking brake
button to apply the electromechanical parking brake.
Danger from toxic exhaust gases when engine is running.
♦ When the engine is running, the exhaust system must al‐
ways be connected to the exhaust gas extractor.

Safety precautions for vehicles with start/stop system

WARNING

Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).

Observe the following precautions to avoid possible injury and/or

irreparable damage to electrical and electronic components:
♦ Switch off ignition before disconnecting and connecting test
equipment.

Caution

When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery.
♦ Always switch off the ignition before disconnecting the
battery.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .

10 Rep. gr.00 - Technical data

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Observe the following precautions if test equipment has to be

used when road-testing the vehicle.

WARNING

Accidents can be caused if the driver is distracted by test

equipment or if test equipment is not secured.
Injuries can be caused if the passenger's airbag is triggered in
a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Always secure test equipment to the rear seat with a strap
and have it operated from there by a second person.

5.2 Safety precautions when working on

high-voltage vehicles
⇒ “5.2.1 Safety precautions for de-energising high-voltage sys‐
tem”, page 11
⇒ “5.2.2 Safety precautions for re-energising high-voltage sys‐
tem”, page 12

5.2.1 Safety precautions for de-energising

high-voltage system
• The high-voltage system may only be de-energised by a suit‐
ably qualified person (Audi high-voltage technician). For a
definition and explanation of the relevant qualifications, please
refer to ⇒ Electrical system, hybrid; Rep. gr. 93 ; General
warning instructions for work on the high-voltage system .
• The system must first be de-energised before any work is done
on the high-voltage system. The types of work for which the
high-voltage system has to be de-energised are indicated in
the instructions for the procedure. For further information on
the procedure for de-energising the high-voltage system
please refer to ⇒ Electrical system, hybrid; Rep. gr. 93 ; De-
energising high-voltage system .
• Read and observe all additional warnings and descriptions for
work on the high-voltage system ⇒ Electrical system, hybrid;
Rep. gr. 93 ; General warning instructions for work on the high-
voltage system .

Note

In the event of queries or uncertainty regarding the terms “elec‐

trically instructed person”, “Audi high-voltage technician”, “Audi
specialist for work on high-voltage systems” or the high-voltage
system itself, the relevant importer must be contacted prior to the
start of all work.

For work that requires de-energising of the high-voltage system,

please note:
The high-voltage system must be de-energised according to the
Guided Fault Finding routine in the ⇒ vehicle diagnostic test‐
er , and ONLY by this method.

5. Safety precautions 11
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) con‐
firms that the system is de-energised and uses the locking
cap - T40262- to ensure that it cannot be re-energised.
The ignition key and the maintenance connector for high-
voltage system - TW - are then stored in a safe place by
the qualified person.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

5.2.2 Safety precautions for re-energising

high-voltage system
• The high-voltage system may only be re-energised by a suit‐
ably qualified person (Audi high-voltage technician). For a
definition and explanation of the relevant qualifications, please
refer to ⇒ Electrical system, hybrid; Rep. gr. 93 ; General
warning instructions for work on the high-voltage system .
• Re-energising the high-voltage system ⇒ Electrical system,
hybrid; Rep. gr. 93 ; Re-energising high-voltage system .
• Read and observe all additional warnings and descriptions for
work on the high-voltage system ⇒ Electrical system, hybrid;
Rep. gr. 93 ; General warning instructions for work on the high-
voltage system .

Note

In the event of queries or uncertainty regarding the terms “elec‐

trically instructed person”, “Audi high-voltage technician”, “Audi
specialist for work on high-voltage systems” or the high-voltage
system itself, the relevant importer must be contacted prior to the
start of all work.

The high-voltage system must be re-energised according to the

Guided Fault Finding routine in the ⇒ vehicle diagnostic test‐
er , and ONLY by this method.

12 Rep. gr.00 - Technical data

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be re-energised by a
suitably qualified person (Audi high-voltage technician).
♦ The system may only be re-energised using the vehicle
diagnostic tester via “Guided Fault Finding”.
♦ The vehicle is then made ready for operation again by the
qualified person (Audi high-voltage technician).
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

5. Safety precautions 13
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

6 Repair instructions
⇒ “6.1 General repair instructions”, page 14
⇒ “6.2 Safety precautions and testing”, page 14
⇒ “6.3 Jacking mode (vehicles with air suspension)”, page 16
⇒ “6.4 Special tools”, page 16
⇒ “6.5 Components”, page 16

6.1 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. The
usual basic safety precautions also naturally apply when carrying
out repair work.
To avoid unnecessary repetition, a number of generally applica‐
ble instructions for the various repair procedures are summarised
here under the heading “Components” ⇒ page 16 . They apply
to the work described in this Manual.

6.2 Safety precautions and testing

WARNING

If repairs to the rear final drive 0BF and 0BE are not carried out
correctly, this can lead to malfunctions of the final drive.
• Tests, repairs and service work may only be performed by
suitably qualified staff.

14 Rep. gr.00 - Technical data

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Correct oil level

♦ Ensure that the rear final drive is filled with specified quantity
of oil ⇒ page 5 .
♦ Eliminate any leaks on the rear final drive, e.g. at sealing sur‐
faces or oil seals. The oil might also escape via the oil escape
holes between the superposition gears on the left side
-arrow 1- or right side -arrow 2- and the rear final drive.

Caution

Malfunction of rear final drive.

♦ Do NOT operate the rear final drive if you have detected
any leaks or if the oil level is low.
♦ Eliminate any leaks on the rear final drive.
♦ Top up any missing ATF or gear oil.
♦ Use only the ATF or gear oil available as a replacement
part ⇒ Electronic parts catalogue .
♦ If the leaks cannot be repaired, the rear final drive must
be renewed.

Rear final drive control functions

WARNING

Malfunction of gearbox/final drive activation

• It is important to follow all instructions closely when re‐
newing components of the gearbox or final drive. Only
then can the correct response and torque control charac‐
teristics of the rear final drive 0BF and 0BE be ensured.

Renewing final drive components

♦ When the all-wheel drive control unit - J492- is renewed, the
learnt values (adaptive values) for the degradation of the final
drive (e.g. clutch wear, oil ageing) must be transferred using
the ⇒ Vehicle diagnostic tester, as otherwise the performance
of the rear final drive can be impaired.
♦ When a superposition gear or the complete rear final drive are
renewed, the clutch classification must be entered again in the
all-wheel drive control unit - J492- ⇒ Vehicle diagnostic tester.
If the clutch classification is not carried out in the all-wheel
drive control unit - J492- , the performance of the rear final
drive will be impaired. In addition, the corresponding classifi‐
cation mark on the rear final drive housing must be made
unrecognisable when a superposition gear has been renewed.
There is a mark for the new classification on the housing of the
new superposition gear.
♦ Do not place the removed rear final drive on the components
of the hydraulic control unit (e.g. clutch valves). This could
damage the components.
Renewing oil pressure and oil temperature sender -G437- and/or
-G640-
♦ After renewing the oil pressure and oil temperature sender -
G437- or the oil pressure and oil temperature sender 2 -
G640- , the identity of the corresponding sender must be re-
adapted in the all-wheel drive control unit - J492- ⇒ Vehicle
diagnostic tester.

6. Repair instructions 15
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Do not renew both oil pressure and oil temperature senders

( -G437- and -G640- ) at the same time, as at least one valid
sender identity is required at any time for the allocation of the
rear final drive to the all-wheel drive control unit - J492- . If both
senders are renewed at the same time, the all-wheel drive
control unit - J492- would interpret this as the replacement of
the rear final drive. This would erase all the learnt values in the
control unit and impair the performance of the rear final drive.
♦ If both oil pressure and oil temperature senders ( -G437- and
-G640- ) have to be renewed due to mechanical damage, e.g.
damage to the connector housing, this should be done in two
steps: After the first sender has been renewed, the identity of
the sender must be re-adapted in the all-wheel drive control
unit - J492- ⇒ Vehicle diagnostic tester. Proceed in the same
manner for the second sender.
♦ If both oil pressure and oil temperature senders ( -G437- and
-G640- have to be renewed due to an electrical fault, the clutch
classification must be entered again in the all-wheel drive con‐
trol unit - J492- ⇒ Vehicle diagnostic tester. In addition, the
ATF must be renewed ⇒ page 117 .
Checking torque distribution
The function 22 - Check torque distribution must be per‐
formed after the following operations:
♦ Work on wiring of rear final drive
♦ Work on valves: clutch valve for all-wheel drive - N445- and
clutch valve 2 for all-wheel drive - N446-
♦ Work on hydraulic control unit
⇒ “3.7 Checking torque distribution”, page 106

6.3 Jacking mode (vehicles with air suspen‐

sion)
Before raising a vehicle with air suspension on a two pillar vehicle
hoist (wheels off the ground) you must first activate the jacking
mode ⇒ Running gear, front-wheel drive and four-wheel drive;
Rep. gr. 00 ; Repair instructions; Lifting suspension to reference
position (vehicles with air suspension) .

6.4 Special tools

For a complete list of special tools used in this Workshop Manual
⇒ Workshop equipment and special tools catalogue .

6.5 Components
Rear final drive
♦ Allocate bolts and other components according to final drive
code letters, refer to ⇒ Electronic parts catalogue .
♦ When installing a new rear final drive unit, check the oil level
in the final drive ⇒ page 107 and the ATF level ⇒ page 116
and top up as required.
♦ Capacities and specifications ⇒ page 5 .
♦ When installing mounting brackets as well as other waxed
components, the contact surfaces must be cleaned. The con‐
tact surfaces must be free of wax and grease.
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.

16 Rep. gr.00 - Technical data

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Environmental and waste disposal regulations for oil

♦ Gear oil and any other type of oil must be handled with care.
♦ Dispose of drained oil properly.
♦ Always adhere to statutory environmental and waste disposal
regulations.
♦ Observe the information shown on the packaging of the oil.
ATF and gear oil
The rear final drive unit 0BF/0BE has separate fillings for ATF and
gear oil.
♦ For the hydraulic system (hydraulic control unit and superpo‐
sition gears, left and right) use only the ATF available as a
replacement part ⇒ Electronic parts catalogue .
♦ For the final drive (gear set and differential) use only the gear
oil available as a replacement part ⇒ Electronic parts cata‐
logue .
♦ Other types of ATF or gear oil will cause malfunctions of the
final drive.

Caution

Gear oil and ATF change

• On some RS models, the gear oil and the ATF must be
changed.
• For change interval, refer to ⇒ Maintenance tables .
• For all other vehicles no change is required.

Oil seals
♦ Lightly lubricate outer circumference of oil seals before instal‐
lation.
♦ The open side of the oil seal should face the side containing
the fluid.
♦ After renewing oil seals, check gear oil level ⇒ page 107 or
ATF level ⇒ page 116 (depending on fitting location of oil seal)
in final drive.
Oil seal for propshaft flange
♦ Pack space between sealing lips -arrow- half-full with sealing
grease - G 052 128 A1- .

6. Repair instructions 17
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Oil seals for flange shafts

♦ Coat space between sealing lips -arrow- with ATF .
O-rings, seals and gaskets
♦ Always renew O-rings, seals, oil seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Lightly lubricate O-rings before installation to prevent them
from being trapped and damaged during assembly.
♦ After renewing gaskets, seals or O-rings, check gear oil level
⇒ page 107 or ATF level ⇒ page 116 (depending on fitting
location) in final drive.

Locking elements
♦ Do not over-stretch circlips.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.

Bolts and nuts

♦ Nuts and bolts for securing covers and housings must be
slackened and tightened in diagonal sequence.
♦ Loosen and tighten particularly sensitive parts in diagonal se‐
quence and in stages, taking care to keep them straight.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and nuts.
♦ Clean the threads of bolts which are secured with locking fluid
using a wire brush (does not apply to propshaft bolts: these
must be renewed). Then apply locking fluid - AMV 185 101 A1-
to bolt threads before installing.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.

18 Rep. gr.00 - Technical data

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

39 – Final drive - rear differential

1 Propshaft
⇒ “1.1 Exploded view - propshaft”, page 19
⇒ “1.2 Removing and installing propshaft”, page 24
⇒ “1.3 Detaching and attaching propshaft at gearbox or at rear
final drive”, page 37
⇒ “1.3.2 Detaching and attaching propshaft at rear final drive”,
page 39
⇒ “1.4 Renewing protective boot”, page 41

1.1 Exploded view - propshaft

⇒ “1.1.1 Exploded view - propshaft with splines on gearbox end”,
page 19
⇒ “1.1.2 Exploded view - propshaft with bolted connection at
gearbox end”, page 22

1.1.1 Exploded view - propshaft with splines

on gearbox end

Note

♦ Refer to general repair instructions ⇒ page 14 .

♦ The propshaft of the type with splines on the gearbox end can
only be separated from the gearbox by removing it completely.
♦ No repair work can be carried out on the propshaft with the
exception of removing, installing and adjusting.
♦ The propshaft should normally be kept straight when it is stor‐
ed or transported.
♦ The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint
or the protective boot can be damaged if the joint is forced
against its stop.
♦ The propshaft must be tied up or supported at one end if it is
detached only at the rear final drive. If necessary, the prop‐
shaft can be bent as far as the stop at the centre joint, but it
must not be subjected to force.
♦ Use counterhold tool - T10172- with adapters - T10172/5- to
slacken and tighten the propshaft bolts.
♦ Always keep the propshaft horizontal while pulling it off or fit‐
ting it on the rear splined shaft of the gearbox.
♦ Observe correct tightening sequence for bolts securing prop‐
shaft to rear final drive ⇒ page 21 .

Note the following before renewing the propshaft due to com‐

plaints concerning noise and/or vibrations.
♦ Check that centre bearing is free of stress or tension.
♦ Remove bolts securing propshaft to rear final drive. Re-tighten
propshaft bolts in specified sequence ⇒ page 21 .

1. Propshaft 19
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

1 - Gearbox
2 - Hose clip
❑ Renew
3 - Propshaft
❑ Removing and installing
⇒ page 24
❑ Detaching and attach‐
ing propshaft at rear fi‐
nal drive ⇒ page 39
❑ Renewing protective
boot ⇒ page 41
4 - Lock plate
5 - Bolt
❑ Self-locking
❑ Always renew
❑ Clean remaining locking
fluid out of tapped holes
in flange shaft on rear fi‐
nal drive. The threads
can be cleaned with a
thread tap
Final drive 0BC, 0BD, 0BF
❑ M8 x 45
❑ Tightening torque and
sequence ⇒ page 21
Final drive 0BE
❑ M10 x 45 x 1
❑ Tightening torque and
sequence ⇒ page 21
6 - Gasket
❑ Renew gasket if dam‐
aged (buckled or kinked)
❑ Renew gasket if rubber coating has become detached
❑ Degrease flange shaft and fit gasket
❑ Different coloured sides can be disregarded for installation
7 - Rear final drive
Removing and installing ⇒ page 45

8 - Centre bearing
9 - Bolt
❑ 20 Nm

20 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Securing propshaft to rear final drive - tightening torque and se‐

quence
• Always renew propshaft bolts -1-.
• Counterhold using counterhold tool - T10172- and adapters -
T10172/5- .
– Tighten bolts -1- in 3 stages as follows:
Stage Bolts Tightening torque/tightening angle
1. -1- Bolt nearest to coloured dots: 30
Nm1)
2. -1- All remaining bolts: 30 Nm
3. -1- All bolts: turn 90° further
• 1) This pushes the CV joint slightly towards the opposite side
and reduces the imbalance.

Heat shield for propshaft - tightening torque

– Tighten bolts -arrows- to 24 Nm.

1. Propshaft 21
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

1.1.2 Exploded view - propshaft with bolted

connection at gearbox end

Note

♦ Refer to general repair instructions ⇒ page 14 .

♦ No repair work can be carried out on the propshaft with the
exception of removing, installing and adjusting.
♦ The propshaft should normally be kept straight when it is stor‐
ed or transported.
♦ The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint
or the protective boot can be damaged if the joint is forced
against its stop.
♦ The propshaft must be tied up or supported at one end if it is
detached only at the gearbox or at the rear final drive. If nec‐
essary, the propshaft can be bent as far as the stop at the
centre joint, but it must not be subjected to force.
♦ Before removing, mark the positions of all parts in relation to
each other. Reinstall in the same position to avoid excessive
imbalance, resulting in bearing damage and rumbling noise.
♦ Use counterhold tool - T10172- with adapters - T10172/5- to
slacken and tighten the propshaft bolts.
♦ After detaching the propshaft from the rear final drive, an ad‐
ditional balancing washer (thicker washer) that may be fitted
between the lock plate and the bolt head (multi-point socket
head bolt) must not be reinstalled.
♦ If problems are reported concerning noise and/or vibration,
check that the centre bearing is stress-free before renewing
the propshaft.

22 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

1 - Rear final drive

❑ Removing and installing
⇒ page 45
2 - Gasket
❑ Renew gasket if dam‐
aged (buckled or
kinked)
❑ Renew gasket if rubber
coating has become de‐
tached
❑ Degrease flange shaft
and fit gasket
❑ Different coloured sides
can be disregarded for
installation
3 - Propshaft
❑ Removing and installing
⇒ page 31
❑ Detaching and attach‐
ing propshaft at gearbox
⇒ page 37
❑ Detaching and attach‐
ing propshaft at rear fi‐
nal drive ⇒ page 39
4 - Balancing washer
❑ Not fitted on all vehicles
❑ May be fitted between a
multi-point socket head
bolt
⇒ Item 5 (page 23)
and a lock plate
⇒ Item 6 (page 23) on
the rear final drive
❑ If fitted, this balancing
washer must not be re-
installed after the propshaft has been detached from the rear final drive.
5 - Bolt
❑ Always renew
❑ Self-locking
❑ Always clean threaded holes for bolts in flange shaft (e.g. with a thread tap)
• On rear final drive
❑ Tightening torque and sequence ⇒ page 24

• On gearbox
❑ 30 Nm + 90°
6 - Lock plate
7 - Centre bearing
8 - Bolt
❑ 20 Nm
9 - Gearbox

1. Propshaft 23
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Securing propshaft to rear final drive - tightening torque and se‐

quence
• Always renew propshaft bolts -1-.
• Counterhold using counterhold tool - T10172- and adapters -
T10172/5- .
– Tighten bolts -1- in 3 stages as follows:
Stage Bolts Tightening torque/tightening angle
1. -1- Bolt nearest to coloured dots: 30
Nm1)
2. -1- All remaining bolts: 30 Nm
3. -1- All bolts: turn 90° further
• 1) This pushes the CV joint slightly towards the opposite side
and reduces the imbalance.

Heat shield for propshaft - tightening torque

– Tighten bolts -arrows- to 24 Nm.

1.2 Removing and installing propshaft

⇒ “1.2.1 Removing and installing propshaft with splines on gear‐
box end”, page 24
⇒ “1.2.2 Removing and installing propshaft with bolted connection
at gearbox end”, page 31

1.2.1 Removing and installing propshaft with

splines on gearbox end
Special tools and workshop equipment required
♦ Retaining tool - VW 785/1 B-

24 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Counterhold tool - T10172-

♦ Adapter -T10172/5-
♦ Hose clip pliers - V.A.G 1275-

♦ High-temperature grease ; refer to ⇒ Electronic parts cata‐

logue
Removing

Note

♦ The propshaft of the type with splines on the gearbox end can
only be separated from the gearbox by removing it completely.
♦ Repairs on the propshaft should preferably be carried out on
a two-pillar hoist.
♦ After unbolting propshaft from rear final drive, tie up or support
end of propshaft.
♦ The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint
or the protective boot can be damaged if the joint is forced
against its stop.
♦ Always keep the propshaft horizontal while pulling it off or fit‐
ting it on the rear splined shaft of the gearbox.

Caution

The flexible joints in the exhaust system can be damaged.

♦ The flexible joint must not be bent further than 10°.
♦ Do not subject flexible joint to tensile load.
♦ Take care not to damage wire mesh on flexible joint.

1. Propshaft 25
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Vehicles with 3.0 ltr. TDI engine and two turbochargers

– Remove particulate filter/SCR catalytic converter ⇒ 6-cylinder
TDI engine (3.0 ltr. 4-valve common rail - generation II); Rep.
gr. 26 ; Emission control system; Removing and installing
particulate filter .

Continued for all vehicles

– Loosen clamp(s) -arrows- and slide towards rear.
– Tie up front silencers or front exhaust pipes (left and right) on
vehicle underside.

– If fitted, remove bolts -arrows- and detach heat shield -1- for
propshaft.

– Cut open hose clip -1- for protective boot on propshaft and
remove hose clip.

Note

-Item 2- can be disregarded.

26 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Audi A6 and A7
– Remove cross-piece -2- ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody trim .

Audi A4, A5 Coupé, A5 Sportback, A5 Cabriolet, Q5, A8

– If fitted, remove cross member -2- (front) and cross member
-3- (rear) ⇒ General body repairs, exterior; Rep. gr. 66 ; Un‐
derbody trim; Exploded view - underbody trim .
Continued for all vehicles
– Remove heat shield -1-.

– Lower rear section of exhaust system at the front and support

using retaining tool - VW 785/1 B- as shown in illustration.

– Check whether there is a factory marking (coloured dot)

-arrow A- and -arrow B- on the propshaft and on the rear final
drive flange.
– If one of these markings is no longer visible, make a new paint
marking accordingly.
• The markings on the propshaft -arrow A- and on the rear final
drive -arrow B- should be aligned.

1. Propshaft 27
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Remove bolts -1- securing propshaft to rear final drive.

– To do so, use counterhold tool - T10172- and adapters -
T10172/5- .

– Adapter -T10172/6- must be used for rear final drive 0BE.

– Remove bolts -arrows- securing centre propshaft bearing.

– Without applying force, kink propshaft as far as stop at centre
bearing.

Note

♦ In some positions, the propshaft can be kinked slightly further.

♦ To do so, turn the propshaft slightly.

– Guide propshaft downwards at rear, past fuel tank and rear

subframe, and detach from gearbox.
Installing
• Tightening torques
⇒ “1.1.1 Exploded view - propshaft with splines on gearbox
end”, page 19 and
⇒ Fig. ““Heat shield for propshaft - tightening torque”“ ,
page 21 .

28 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Note

♦ Remove old, dried-out high-temperature grease from CV joint

and flange for propshaft. Put in exactly the same quantity of
fresh high-temperature grease .
♦ Clean remaining locking fluid out of tapped holes in flange
shaft on rear final drive. The threads can be cleaned with a
thread tap. Otherwise the securing bolts can shear off when
they are screwed in.
♦ Renew self-locking bolts for propshaft.
♦ Renew hose clip -1- for protective boot -2- on propshaft.
♦ Check for damage to gasket for propshaft on rear final drive
flange (kinked gasket or partially detached rubber coating). A
damaged gasket must be renewed.
♦ Wipe off splines of rear splined shaft on gearbox with a cloth
before sliding on propshaft. Do not apply grease to splines.

– Fit propshaft onto gearbox first.

• Do not bend further than 10° when fitting propshaft on splines.
• After sliding the propshaft approx. 50 mm onto the rear splined
shaft of the gearbox, turn it slightly to ensure that the splines
on the shaft engage in the internal splines of the propshaft.
• Push propshaft onto splines of rear splined shaft as far as stop.
– Without applying force, kink propshaft as far as stop at centre
bearing.

Note

♦ In some positions, the propshaft can be kinked slightly further.

♦ To do so, turn the propshaft slightly.

– Guide propshaft upwards at rear at subframe and fuel tank.

– Screw in securing bolts -arrows- so that centre bearing can still

be moved.

1. Propshaft 29
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Fit propshaft on rear final drive, paying attention to installation

position:
• The markings on the propshaft -arrow A- and on the rear final
drive -arrow B- should be aligned.
• Maximum misalignment of markings: 30°
– Screw in new bolts by hand until they make contact, but do not
tighten.

– Align hose clip -1- for protective boot on propshaft with shaped
sections -2- and tighten using hose clip pliers - V.A.G 1275-
or similar.

Note

Push the propshaft slightly towards the rear in order to be able to

apply the hose clip pliers - V.A.G 1275- properly.

– Tighten bolts for propshaft -1-. Follow correct tightening se‐

quence ⇒ page 21 .

– Secure centre propshaft bearing to body so it is free of stress

and tighten. Tightening torque ⇒ Item 9 (page 20)

30 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

The remaining installation steps are carried out in reverse se‐

quence; note the following:
– If fitted, bolt heat shield -A- onto gearbox -arrows-. Tightening
torque ⇒ page 21

– Install heat shield -1- ⇒ General body repairs, exterior; Rep.

gr. 66 ; Underbody trim; Exploded view - underbody trim .
– If originally fitted, install cross member -2- (front) and cross
member -3- (rear) ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim .

Vehicles with 3.0 ltr. TDI engine and two turbochargers

– Install particulate filter/SCR catalytic converter ⇒ 6-cylinder
TDI engine (3.0 ltr. 4-valve common rail - generation II); Rep.
gr. 26 ; Emission control system; Removing and installing
particulate filter .
– Install exhaust system and perform stress-free alignment ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silenc‐
ers .

1.2.2 Removing and installing propshaft with

bolted connection at gearbox end
Special tools and workshop equipment required

1. Propshaft 31
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Assembly tool - 3139-

♦ Counterhold tool - T10172- with adapters - T10172/5-

♦ Engine and gearbox jack - V.A.G 1383 A- with universal sup‐

port - V.A.G 1359/2-

♦ High-temperature grease ; refer to ⇒ Electronic parts cata‐

logue
Removing propshaft
♦ Observe notes ⇒ page 22 .
♦ Repairs on the propshaft should be carried out on a two pillar
hoist.

Note

The flexible pipe connection (de-coupling element) in the front

exhaust pipe must not be bent more than 10° - otherwise it can
be damaged.

– Unfasten clamp(s) -arrows- and disconnect exhaust system.

– Tie front exhaust pipe(s) up to side of underbody.

32 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Remove rear section of exhaust system -2- ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers; Exploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

Audi A4, Audi A5

– Remove cross member -1-.
– Detach heat shield -3- from body -arrows-.

Audi Q5
– Remove front cross member -2- and rear cross member -3-.
– Detach heat shield -1- from body.

Continued for all vehicles

– If fitted, detach heat shield -A- from gearbox -arrows-.

– Check whether there is a factory marking (coloured dot)

-arrow A- and -arrow B- on the propshaft and on the propshaft
flange on the rear final drive.
– If one of these markings is no longer visible (for example
-arrow A- on the propshaft), make a new coloured marking
accordingly.
• The markings on the propshaft -arrow A- and on the rear final
drive -arrow B- should be aligned.

1. Propshaft 33
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Attach assembly tool - 3139- and tighten plastic nuts.

Note

Do not fit assembly tool onto balance plates.

– Remove bolts -arrows- securing centre bearing.

– Remove securing bolts from connection between propshaft

and gearbox (counterhold using counterhold tool - T10172-
and -T10172/5- or -T10172/6- ).
– Remove propshaft from gearbox and support propshaft with
engine and gearbox jack - V.A.G 1383 A- .

34 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Remove bolts -1- (6x) on rear CV joint.

– Use counterhold tool - T10172- with adapters - T10172/5- or
-T10172/6-
.
– Remove propshaft.

Note

The propshaft must be kept straight when it is stored or transpor‐

ted.

Installing propshaft
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
♦ Remove old, dried-out high-temperature grease from CV joints
and flanges for propshaft. Put in exactly the same quantity of
fresh high-temperature grease .
♦ Clean all remaining locking fluid out of the tapped holes in the
propshaft flange shafts on the gearbox and rear final drive. The
threads can be cleaned with a thread tap. Otherwise the se‐
curing bolts can shear off when they are screwed in.
♦ After detaching the propshaft from the rear final drive, the ad‐
ditional balancing washer (thicker washer) that may be fitted
between the lock plate and one of the securing bolts must not
be reinstalled.
♦ Always install new securing bolts for propshaft (self-locking
bolts).
♦ Note correct position of propshaft: the central CV joint is loca‐
ted behind the centre bearing and towards the rear final drive.
♦ Check for damage to gasket for propshaft on rear final drive
flange and on gearbox (kinked gasket or partially detached
rubber coating). A damaged gasket must be renewed.

– Fit propshaft, paying attention to installation position at rear

final drive:
• The markings on the propshaft -arrow A- and on the rear final
drive -arrow B- should be aligned.
• Maximum misalignment of markings: 30°.
– Screw in new bolts by hand until they make contact, but do not
tighten.

1. Propshaft 35
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Screw in securing bolts -arrows- so that centre bearing can still

be moved.

– Tighten bolts -1- at rear of propshaft. Follow correct tightening

sequence ⇒ page 24 .

– Tighten bolts securing propshaft (front end). Tightening torque

⇒ Item 5 (page 23)
– Remove assembly tool - 3139- .
– Secure centre propshaft bearing to body so it is free of stress
and tighten. Tightening torque ⇒ Item 8 (page 23)

– If fitted, bolt heat shield -A- onto gearbox -arrows-. Tightening

torque ⇒ page 24

36 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Install heat shield -1-.

– If originally fitted, install cross member -2- (front) and cross
member -3- (rear) ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim .
– Install exhaust system and perform stress-free alignment ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silenc‐
ers .

1.3 Detaching and attaching propshaft at

gearbox or at rear final drive
⇒ “1.3.1 Detaching and attaching propshaft at gearbox with bolted
connection at gearbox end”, page 37
⇒ “1.3.2 Detaching and attaching propshaft at rear final drive”,
page 39

1.3.1 Detaching and attaching propshaft at

gearbox with bolted connection at gear‐
box end
Special tools and workshop equipment required
♦ Counterhold tool - T10172- with adapters
♦ Adapter -T10172/5- (M8 bolts)
♦ Adapter -T10172/6- (M10 bolts)

♦ High-temperature grease ; refer to ⇒ Electronic parts cata‐

logue
Detaching propshaft
♦ Observe notes ⇒ page 22 .
♦ Repairs on the propshaft should be carried out on a two pillar
hoist.

1. Propshaft 37
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Note

The flexible pipe connection (de-coupling element) in the front

exhaust pipe must not be bent more than 10° - otherwise it can
be damaged.

– Unfasten clamps -1- and -2- and disconnect exhaust system.

– Tie front exhaust pipe(s) up to side of underbody.

– If fitted, detach heat shield -A- from gearbox -arrows-.

– Remove securing bolts from connection between propshaft

and gearbox (counterhold using counterhold tool - T10172-
and -T10172/5- ).
– Secure propshaft to side of underbody.
Attaching propshaft
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
♦ Remove old, dried-out high-temperature grease from CV joint
and flange for propshaft. Put in exactly the same quantity of
fresh high-temperature grease .
♦ Clean remaining locking fluid out of tapped holes in flange
shaft on gearbox. The threads can be cleaned with a thread
tap. Otherwise the securing bolts can shear off when they are
screwed in.
♦ Always install new securing bolts for propshaft (self-locking
bolts).
♦ Check for damage to gasket for propshaft on gearbox flange
(kinked gasket or partially detached rubber coating). A dam‐
aged gasket must be renewed.

– Bring propshaft into position and fit new bolts on CV joint.

– Tighten bolts securing propshaft (front end). Tightening torque
⇒ Item 5 (page 23)
• Use counterhold tool - T10172- with adapters - T10172/5- .

38 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– If fitted, bolt heat shield -A- onto gearbox -arrows-. Tightening

torque ⇒ page 24
– Assemble exhaust system and perform stress-free alignment
⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - si‐
lencers .

1.3.2 Detaching and attaching propshaft at

rear final drive
Special tools and workshop equipment required
♦ Counterhold tool - T10172-

♦ Adapter -T10172/5- (M8 bolts)

♦ Adapter -T10172/6- (M10 bolts)
♦ High-temperature grease ; refer to ⇒ Electronic parts cata‐
logue
♦ Please refer to notes ⇒ page 22 .
♦ Repairs on the propshaft should be carried out on a two pillar
hoist.
Detaching propshaft from rear final drive
– Disconnect exhaust system at clamps -1- and -2-.
– Tie front exhaust pipe(s) up to side of underbody.

Note

♦ The flexible pipe connection (de-coupling element) in the front

exhaust pipe must not be bent more than 10° - otherwise it can
be damaged. To prevent this, tie up front exhaust pipes to body
on one side.
♦ A second mechanic is required for removing the rear section
of the exhaust system.

– Remove rear section of exhaust system ⇒ Rep. gr. 26 ; Ex‐

haust pipes/silencers; Exploded view - silencers .

1. Propshaft 39
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Check whether there is a factory marking (coloured dot)

-arrow A- and -arrow B- on the propshaft and on the propshaft
flange on the rear final drive.
– If one of these markings is no longer visible (for example
-arrow A- on the propshaft), make a new paint marking ac‐
cordingly.
• The markings on the propshaft -arrow A- and on the rear final
drive -arrow B- should be aligned.

– Remove bolts -1- (6x) on rear CV joint.

– To do so, use counterhold tool - T10172- and adapters -
T10172/5- or -T10172/6- .
– Separate propshaft from rear final drive and move clear to one
side on subframe.
Attaching propshaft to rear final drive
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
♦ Remove old, dried-out high-temperature grease from CV joint
and flange for propshaft. Put in exactly the same quantity of
fresh high-temperature grease .
♦ Clean remaining locking fluid out of tapped holes in flange
shaft on rear final drive. The threads can be cleaned with a
thread tap. Otherwise the securing bolts can shear off when
they are screwed in.
♦ After detaching the propshaft from the rear final drive, the ad‐
ditional balancing washer (thicker washer) that may be fitted
between the lock plate and one of the securing bolts must not
be reinstalled.
♦ Always install new securing bolts for propshaft (self-locking
bolts).
♦ Check for damage to gasket for propshaft on rear final drive
flange (kinked gasket or partially detached rubber coating). A
damaged gasket must be renewed.

– Fit propshaft on rear final drive, paying attention to installation

position:
• The markings on the propshaft -arrow A- and on the rear final
drive -arrow B- should be aligned.
• Maximum misalignment of markings: 30°.

40 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Install and tighten new securing bolts -1- for propshaft. Follow
correct tightening sequence ⇒ page 24 .
– Install rear section of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Exploded view - silencers .

1.4 Renewing protective boot

⇒ “1.4.1 Renewing protective boot for propshaft with splines on
gearbox end”, page 41

1.4.1 Renewing protective boot for propshaft

with splines on gearbox end
Special tools and workshop equipment required
♦ Flanging tool - T40261-

♦ Hose clip - ∅ 23 ... 35 mm-

Procedure
– Remove propshaft ⇒ page 24 .
– Clamp propshaft in vice using protective jaw covers -
T40261/1- as shown in illustration.

1. Propshaft 41
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Using a screwdriver, carefully open an initial section of seam

between metal sleeve -1- and propshaft joint.
• Take care not to damage surface of propshaft joint.

– Open rest of seam on metal sleeve -arrow- using side-cutting

pliers.
– Detach old protective boot with metal sleeve from propshaft
joint.

– Destroy support ring using water pump pliers -arrows- and re‐
move protective boot with metal sleeve.

Note

Inner part of joint and balls remain in propshaft joint.

– Wipe off old excess grease.

– Regrease propshaft joint with grease from installation kit.

Note

Use the same amount of grease as you wiped off plus the amount
that remained in the old protective boot.

– Clean sealing surface -arrow- on propshaft joint -2-.

– Smooth down any scoring caused by removal of old protective
boot.
– Insert new O-ring -1- in groove.

42 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Slide support ring -2- into opening of protective boot -1-.

• Installation direction: Recess -arrow A- is inserted into protec‐
tive boot.
• Teeth -arrow B- on support ring should be visible at edge of
opening on protective boot.

– Roll back protective boot -2- inside metal sleeve -1-.

– Slide hose clip -arrow- onto exposed teeth of support ring
-3-, as shown in illustration.
• Do not cover ends of support ring.

– Tighten hose clip -2- until teeth -1- of support ring can be in‐
serted into groove -3- on inner part of joint.
– Release and detach hose clip -2-.
• Teeth of support ring must mate with groove on inner part of
joint -arrow-.
– Push metal sleeve of protective boot onto joint as far as stop.

1. Propshaft 43
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Apply flanging tool - T40261- to metal sleeve so that stops of

guide rollers -arrow- are resting on edge of metal sleeve.
– Turn flanging tool -T40261- back and forth to close seam of
metal sleeve.
• Angle of rotation must be at least 90° when moving tool back
and forth.
• Tighten adjusting wheel on flanging tool -T40261- as you
move tool back and forth.
• Seam is finished when adjusting wheel of -T40261- can no
longer be turned without difficulty.

44 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

2 Final drive
⇒ “2.1 Exploded view - final drive”, page 45
⇒ “2.2 Removing and installing final drive”, page 48

2.1 Exploded view - final drive

⇒ “2.1.1 Exploded view - final drive 0BC, 0BD”, page 45
⇒ “2.1.2 Exploded view - final drive 0BE, 0BF”, page 47

2.1.1 Exploded view - final drive 0BC, 0BD

Rear final drive

1 - Subframe
♦ Removing and installing ⇒
Running gear, axles, steer‐
ing; Rep. gr. 42 ; Subframe;
Exploded view - subframe
2 - Bolt
❑ 95 Nm
3 - Bolt
❑ 55 Nm
4 - Bolt
❑ 55 Nm
❑ Used to secure a damp‐
er weight on some ver‐
sions ⇒ page 45
5 - Heat shield
6 - Bolt
❑ 20 Nm
7 - Drive shaft
❑ Removing and installing
⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Drive shaft; Removing
and installing drive
shaft .
8 - Rear final drive
❑ With damper weight
(depending on version)
⇒ page 45
❑ ⇒ “2.2 Removing and in‐
stalling final drive”, page
48
9 - Propshaft
❑ Removing and installing ⇒ page 24
❑ Detaching and attaching propshaft at rear final drive ⇒ page 39
10 - Cross member

Damper weights on rear final drive

2. Final drive 45
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

1 - Bolt
❑ 22 Nm
2 - Damper weight
❑ Depends on version; re‐
fer to ⇒ Electronic parts
catalogue
3 - Rear final drive
❑ ⇒ “2.2 Removing and in‐
stalling final drive”, page
48
4 - Cross member
5 - Damper weight
❑ Depends on vehicle ver‐
sion; refer to ⇒ Elec‐
tronic parts catalogue
6 - Bolt
❑ Tightening torque
⇒ Item 4 (page 45)
7 - Damper weight
❑ Depends on version; re‐
fer to ⇒ Electronic parts
catalogue
8 - Washer
9 - Bolt
❑ Tightening torque
⇒ Item 4 (page 45)

46 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

2.1.2 Exploded view - final drive 0BE, 0BF

1 - Bolt
❑ 55 Nm
2 - Subframe
❑ Exploded view ⇒ Run‐
ning gear, axles, steer‐
ing; Rep. gr. 42 ; Sub‐
frame; Exploded view -
subframe
3 - Propshaft
❑ Exploded view
⇒ page 19
❑ Removing and installing
⇒ page 24
4 - Rear final drive
❑ ⇒ “2.2 Removing and in‐
stalling final drive”, page
48
❑ Additional work required
after renewing rear final
drive ⇒ page 88
5 - Drive shaft
❑ Exploded view ⇒ Run‐
ning gear, axles, steer‐
ing; Rep. gr. 42 ; Drive
shaft; Removing and in‐
stalling drive shaft
6 - Heat shield
7 - Bolt
❑ 20 Nm
8 - Bolt
❑ 95 Nm

2. Final drive 47
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

2.2 Removing and installing final drive

⇒ “2.2.1 Removing and installing final drive 0BC for Audi A4, A5,
A6, A7, Q5 (not Q5 hybrid)”, page 48
⇒ “2.2.2 Removing and installing final drive 0BC for Audi Q5 hy‐
brid”, page 55
⇒ “2.2.3 Removing and installing final drive 0BC for Audi A8”,
page 63
⇒ “2.2.4 Removing and installing final drive 0BD for Audi A4, A5,
Q5”, page 70
⇒ “2.2.5 Removing and installing final drive 0BF for Audi A4, A5,
A6, A7, Q5”, page 76
⇒ “2.2.6 Removing and installing final drive 0BF for Audi RS 4,
RS 5”, page 82
⇒ “2.2.7 Removing and installing final drive 0BE, 0BF for Audi A8”,
page 85
⇒ “2.2.8 Additional work required after renewing final drive 0BE,
0BF”, page 88

2.2.1 Removing and installing final drive 0BC

for Audi A4, A5, A6, A7, Q5 (not Q5 hy‐
brid)
Removing ⇒ page 49
Installing ⇒ page 52
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

♦ Tensioning strap - T10038-

48 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Support - T10149-

♦ Counterhold tool - T10172- with adapters - T10172/5-

♦ Socket - T40154-

Removing:
Refer to general repair instructions ⇒ page 14 .
– Place vehicle on lifting platform.
– Detach wheel trim from rear left wheel (on vehicles with light
alloy wheels, pull off trim cap using puller from vehicle tool kit).
– Remove rear left wheel.

2. Final drive 49
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Vehicles with 6-cylinder or 8-cylinder engine (except Q5)

– Remove rear cross member -1-.
– Remove rear section of exhaust system -2- ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers; Exploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Re-attach rear cross member -1- to body.

Continued for all vehicles
– Detach heat shield -3- from body -arrows-.

– Detach propshaft from rear final drive ⇒ page 39 .

– Place a block of wood -A- (approx. 40 mm high) on rear cross

member -C- to support propshaft -B-.

Note

♦ On the Audi Q5, the propshaft -B- is supported by the heat

shield below the centre bearing.
♦ The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint
or the protective boot can be damaged if the joint is forced
against its stop.

– Remove bolts -arrows- securing centre propshaft bearing.

– Push propshaft forwards and at the same time pull it off rear
final drive.
– Tie propshaft up to one side on subframe.

50 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Detach heat shield -A- for drive shaft (left-side) from cross
member/rear final drive -arrows-.

– Unbolt drive shafts on both sides -1- and -3-.

– Slacken off bolts -2- approx. 3 turns.
– Remove bolt -4-.

– Place engine and gearbox jack - V.A.G 1383 A- with universal

gearbox support - V.A.G 1359/2- and a suitable block of wood
-A- (approx. 80 mm high) below rear final drive.

Note

Make sure that universal gearbox support - V.A.G 1359/2- does

not make contact with fuel tank.

– Remove bolts -1- (bottom bolts securing cross member to rear

final drive) and -2-.

– Remove 2 top bolts securing cross member -B- to rear final

drive.
– For this step, guide socket - T40154- through holes in sub‐
frame -A-. If necessary, move final drive slightly to either side.

2. Final drive 51
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Then push final drive -A- slightly forwards.

– Turn cross member -B- towards the bottom left -arrow 1-,
guide past final drive -arrow 2- and remove.

Note

♦ A 2nd mechanic is required for the next steps when removing

the rear final drive.
♦ Before lifting the rear left suspension, the vehicle must be se‐
cured to the lifting arm of the lifting platform with tensioning
strap - T10038- .

– Take out engine and gearbox jack - V.A.G 1383 A- from below
rear final drive; 2nd mechanic must hold final drive to prevent
it from dropping.
– Attach support - T10149- to engine and gearbox jack - V.A.G
1383 A- .

– Attach support - T10149- to rear left wheel hub using wheel

bolt -arrow A-.
– Using engine and gearbox jack - V.A.G 1383 A- , lift rear left
suspension until vehicle starts to come clear of lifting arm -1-
of lifting platform -arrow B-. Do not lift vehicle further.

WARNING

♦ Do not raise or lower vehicle while engine and gearbox

jack - V.A.G 1383 A- is positioned under the vehicle.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle for longer than necessary.

– 2nd mechanic must now push rear final drive -1- towards left
side of vehicle in direction of -arrow-.
– Guide drive shaft (right-side) -5- upwards out of flange shaft
-4- of rear final drive.
– Then disengage drive shaft (left-side) -3- and, with assistance
of 2nd mechanic, detach final drive rearwards from subframe
-2-.

– When renewing a rear final drive on which a damper weight

-arrow- is fitted, damper weight must be transferred to new
rear final drive ⇒ page 45 .
Installing:
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
• Tightening torques ⇒ page 45

52 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– With assistance of 2nd mechanic, bring rear final drive -1- into
installation position on subframe -2-.
– Fit drive shaft (left-side) -arrow 3- into flange shaft of final drive.
– 2nd mechanic must now push rear final drive -1- towards left
side of vehicle in direction of -arrow-.
– Then fit drive shaft (right-side) -5- into flange shaft -4- of final
drive.
– Detach engine and gearbox jack - V.A.G 1383 A- with support
- T10149- from rear left suspension.

– Place engine and gearbox jack - V.A.G 1383 A- with universal

gearbox support - V.A.G 1359/2- and a suitable block of wood
(approx. 80 mm high) below rear final drive -A-.
– Then push final drive -A- slightly forwards.
– Turn cross member -B- towards top left in opposite direction
to -arrow 1- and bring into position, guiding past final drive
-arrow 2-.

– Now tighten 4 bolts securing cross member -B- to rear final

drive in diagonal sequence. Tightening torque
⇒ Item 4 (page 45)
– For this step, guide socket - T40154- through holes in sub‐
frame -A-. If necessary, move final drive slightly to either side.

2. Final drive 53
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Screw in bolts -2- and -4- and tighten hand-tight initially.

Note

For illustration purposes the final drive is shown without engine

and gearbox jack - V.A.G 1383 A- and universal gearbox support
- V.A.G 1359/2- .

– Tighten bolt -4-. Tightening torque ⇒ Item 3 (page 45)

– Then tighten bolts -2-. Tightening torque ⇒ Item 2 (page 45)
– Take out engine and gearbox jack - V.A.G 1383 A- from below
final drive.
– Secure drive shafts -1- (left-side) and -3- (right-side) ⇒ Run‐
ning gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing
and installing drive shaft .

– Install heat shield -A- for drive shaft (left-side) on cross mem‐
ber/rear final drive -arrows- ⇒ Item 6 (page 45) .

– Bolt propshaft onto rear final drive ⇒ page 40 .

– Secure centre propshaft bearing to body so it is free of stress.
Tightening torque ⇒ Item 8 (page 23)
– Check gear oil level in rear final drive ⇒ page 107 .

– Secure heat shield -3- to body -arrows-.

– Install rear section of exhaust system and perform stress-free
alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers .
– If originally fitted, install cross member -1- ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view
- underbody trim .
– Fit rear wheel (left-side) and tighten wheel bolts ⇒ Running
gear, axles, steering; Rep. gr. 44 ; Wheels, tyres .

54 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

2.2.2 Removing and installing final drive 0BC

for Audi Q5 hybrid
Removing ⇒ page 56
Installing ⇒ page 60
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

♦ Tensioning strap - T10038-

♦ Support - T10149-

♦ Counterhold tool - T10172- with adapters - T10172/5-

2. Final drive 55
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Socket - T40154-

Removing:
Observe safety precautions ⇒ page 10 .
Refer to general repair instructions ⇒ page 14 .
– Place vehicle on lifting platform.
De-energising high-voltage system

WARNING

Observe general warning instructions for work on the high-

voltage system ⇒ Electrical system, hybrid; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

The high-voltage system must be de-energised according to the

Guided Fault Finding routine in the ⇒ vehicle diagnostic test‐
er , and ONLY by this method.

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) con‐
firms that the system is de-energised and uses the locking
cap - T40262- to ensure that it cannot be re-energised.
The ignition key and the maintenance connector for high-
voltage system - TW - are then stored in a safe place by
the qualified person.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

56 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Note

♦ De-energising high-voltage system:

♦ Connect vehicle diagnostic tester.
♦ Select Guided Fault Finding mode.
♦ Using the GoTo button, select the following menu options in
succession.
♦ Function/Component Selection
♦ Body
♦ Electrical system
♦ Self-diagnosis-compatible systems
♦ 8C - Hybrid battery management -J840
♦ 8C - Hybrid battery management, functions
♦
♦ 51 - De-energise high-voltage system (Rep. Gr. 93)

– Detach wheel trim from rear left wheel (on vehicles with light
alloy wheels, pull off trim cap using puller from vehicle tool kit).
– Remove rear left wheel.
– Unfasten clamps -1- and -2- and remove rear section of ex‐
haust system ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Ex‐
ploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Detach propshaft from rear final drive ⇒ page 39 .

2. Final drive 57
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Remove bolts -arrows- securing centre propshaft bearing.

– Push propshaft forwards and at the same time pull it off rear
final drive.

Note

♦ The propshaft is supported by the heat shield under the centre

bearing.
♦ The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint
or the protective boot can be damaged if the joint is forced
against its stop.

– Tie propshaft up to one side on subframe.

– Remove bolt -3- for potential equalisation line -2-.

– Detach heat shield -A- for drive shaft (left-side) from cross
member/rear final drive -arrows-.

– Unbolt drive shafts on both sides -1- and -3-.

– Slacken off bolts -2- approx. 3 turns.
– Remove bolt -4-.

58 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Place engine and gearbox jack - V.A.G 1383 A- with universal

gearbox support - V.A.G 1359/2- and a suitable block of wood
-A- (approx. 80 mm high) below rear final drive.

Note

Make sure that universal gearbox support - V.A.G 1359/2- does

not make contact with fuel tank.

– Remove bolts -1- (bottom bolts securing cross member to rear

final drive) and -2-.

– Remove 2 top bolts securing cross member -B- to rear final

drive.
– For this step, guide socket - T40154- through holes in sub‐
frame -A-. If necessary, move final drive slightly to either side.

– Then push final drive -A- slightly forwards.

– Turn cross member -B- towards the bottom left -arrow 1-,
guide past final drive -arrow 2- and remove.

Note

♦ A 2nd mechanic is required for the next steps when removing

the rear final drive.
♦ Before lifting the rear left suspension, the vehicle must be se‐
cured to the lifting arm of the lifting platform with tensioning
strap - T10038- .

– Take out engine and gearbox jack - V.A.G 1383 A- from below
rear final drive; 2nd mechanic must hold final drive to prevent
it from dropping.
– Attach support - T10149- to engine and gearbox jack - V.A.G
1383 A- .

– Attach support - T10149- to rear left wheel hub using wheel

bolt -arrow A-.
– Using engine and gearbox jack - V.A.G 1383 A- , lift rear left
suspension until vehicle starts to come clear of lifting arm -1-
of lifting platform -arrow B-. Do not lift vehicle further.

WARNING

♦ Do not raise or lower vehicle while engine and gearbox

jack - V.A.G 1383 A- is positioned under the vehicle.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle for longer than necessary.

2. Final drive 59
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– 2nd mechanic must now push rear final drive -1- towards left
side of vehicle in direction of -arrow-.
– Guide drive shaft (right-side) -5- upwards out of flange shaft
-4- of rear final drive.
– Then disengage drive shaft (left-side) -3- and, with assistance
of 2nd mechanic, detach final drive rearwards from subframe
-2-.

– When renewing a rear final drive on which a damper weight

-arrow- is fitted, damper weight must be transferred to new
rear final drive ⇒ page 45 .
Installing:
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
• Tightening torques ⇒ page 45

WARNING

Working on vehicles with high-voltage wiring:

• Do not support yourself or tools on high-voltage wiring or
associated components --> this can damage the insula‐
tion.
• High-voltage wiring must not be excessively bent or
kinked --> this can damage the insulation.
• The round high-voltage connectors are colour-coded with
an external coloured ring and are provided with mechan‐
ical coding or guide lugs. It is important to observe this
coding when joining up the round high-voltage connec‐
tors, otherwise the connectors can be damaged.

– With assistance of 2nd mechanic, bring rear final drive -1- into
installation position on subframe -2-.

– Fit drive shaft (left-side) -arrow 3- into flange shaft of final drive.
– 2nd mechanic must now push rear final drive -1- towards left
side of vehicle in direction of -arrow-.
– Then fit drive shaft (right-side) -5- into flange shaft -4- of final
drive.
– Detach engine and gearbox jack - V.A.G 1383 A- with support
- T10149- from rear left suspension.

60 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Place engine and gearbox jack - V.A.G 1383 A- with universal

gearbox support - V.A.G 1359/2- and a suitable block of wood
(approx. 80 mm high) below rear final drive -A-.
– Then push final drive -A- slightly forwards.
– Turn cross member -B- towards top left in opposite direction
to -arrow 1- and bring into position, guiding past final drive
-arrow 2-.

– Now tighten 4 bolts securing cross member -B- to rear final

drive in diagonal sequence. Tightening torque
⇒ Item 4 (page 45)
– For this step, guide socket - T40154- through holes in sub‐
frame -A-. If necessary, move final drive slightly to either side.

– Screw in bolts -2- and -4- and tighten hand-tight initially.

Note

For illustration purposes the final drive is shown without engine

and gearbox jack - V.A.G 1383 A- and universal gearbox support
- V.A.G 1359/2- .

– Tighten bolt -4-. Tightening torque ⇒ Item 3 (page 45)

– Then tighten bolts -2-. Tightening torque ⇒ Item 2 (page 45)
– Take out engine and gearbox jack - V.A.G 1383 A- from below
final drive.
– Secure drive shafts -1- (left-side) and -3- (right-side) ⇒ Run‐
ning gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing
and installing drive shaft .

2. Final drive 61
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Bolt potential equalisation line -2- onto rear final drive.

• Tightening torque for bolt -3- on final drive: 20 Nm

– Install heat shield -A- for drive shaft (left-side) on cross mem‐
ber/rear final drive -arrows- ⇒ Item 6 (page 45) .

62 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Bolt propshaft onto rear final drive ⇒ page 40 .

– Secure centre propshaft bearing to body so it is free of stress.
Tightening torque ⇒ Item 8 (page 23)
– Check gear oil level in rear final drive ⇒ page 107 .
– Install rear section of exhaust system and perform stress-free
alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers .
– Fit rear wheel (left-side) and tighten wheel bolts ⇒ Running
gear, axles, steering; Rep. gr. 44 ; Wheels, tyres .
Re-energising high-voltage system
The high-voltage system must be re-energised according to the
Guided Fault Finding routine in the vehicle diagnostic tester ,
and ONLY by this method.

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be re-energised by a
suitably qualified person (Audi high-voltage technician).
♦ The system may only be re-energised using the vehicle
diagnostic tester via “Guided Fault Finding”.
♦ The vehicle is then made ready for operation again by the
qualified person (Audi high-voltage technician).
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ Re-energising high-voltage system:

♦ Connect vehicle diagnostic tester.
♦ Select Guided Fault Finding mode.
♦ Using the GoTo button, select the following menu options in
succession.
♦ Function/Component Selection
♦ Body
♦ Electrical system
♦ Self-diagnosis-compatible systems
♦ 8C - Hybrid battery management -J840
♦ 8C - Hybrid battery management, functions
♦ 51 - Re-energise high-voltage system (Rep. Gr. 93)

2.2.3 Removing and installing final drive 0BC

for Audi A8
Removing ⇒ page 65
Installing ⇒ page 67

2. Final drive 63
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Special tools and workshop equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

♦ Tensioning strap - T10038-

♦ Support - T10149-

♦ Counterhold tool - T10172- with adapters - T10172/5-

64 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Socket - T40154-

Removing:
Refer to general repair instructions ⇒ page 14 .
– Place vehicle on lifting platform.
– Remove rear left wheel.
– Remove rear cross member -1-.

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Remove rear section -2- of exhaust system ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers; Exploded view - silencers .
– Detach propshaft from rear final drive ⇒ page 39 .

– To support propshaft -B-, place a wooden block -A- (approx.

40 mm high) on rear cross member -C-.

Note

The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint or
the protective boot can be damaged if the joint is forced against
its stop.

– Remove bolts -arrows- securing centre propshaft bearing.

– Push propshaft forwards and at the same time pull it off rear
final drive.
– Tie propshaft to one side.

2. Final drive 65
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Detach heat shield -A- for drive shaft (left-side) from cross
member/rear final drive -arrows-.

– Unbolt drive shafts on both sides -1- and -3-.

– Slacken off bolts -2- approx. 3 turns.
– Remove bolt -4-.

– Place engine and gearbox jack - V.A.G 1383 A- with universal

gearbox support - V.A.G 1359/2- and a suitable block of wood
-A- (approx. 80 mm high) below rear final drive.

Note

Make sure that universal gearbox support - V.A.G 1359/2- does

not make contact with fuel tank.

– Remove bolts -1- (bottom bolts securing cross member to rear

final drive) and -2-.

– Remove 2 top bolts securing cross member -B- to rear final

drive.
– For this step, guide socket - T40154- through holes in sub‐
frame -A-. If necessary, move final drive slightly to either side.

66 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Then push final drive -A- slightly forwards.

– Turn cross member -B- towards the bottom left -arrow 1-,
guide past final drive -arrow 2- and remove.

Note

♦ A 2nd mechanic is required for the next steps when removing

the rear final drive.
♦ Before lifting the rear left suspension, the vehicle must be se‐
cured to the lifting arm of the lifting platform with tensioning
strap - T10038- .

– Take out engine and gearbox jack - V.A.G 1383 A- from below
rear final drive; 2nd mechanic must hold final drive to prevent
it from dropping.
– Attach support - T10149- to engine and gearbox jack - V.A.G
1383 A- .

– Attach support - T10149- to rear left wheel hub using wheel

bolt -arrow A-.
– Using engine and gearbox jack - V.A.G 1383 A- , lift rear left
suspension until vehicle starts to come clear of lifting arm -1-
of lifting platform -arrow B-. Do not lift vehicle further.

WARNING

♦ Do not raise or lower vehicle while engine and gearbox

jack - V.A.G 1383 A- is positioned under the vehicle.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle for longer than necessary.

– 2nd mechanic must now push rear final drive -1- towards left
side of vehicle in direction of -arrow-.
– Guide drive shaft (right-side) -5- upwards out of flange shaft
-4- of rear final drive.
– Then disengage drive shaft (left-side) -3- and, with assistance
of 2nd mechanic, detach final drive rearwards from subframe
-2-.

– When renewing a rear final drive on which a damper weight

-arrow- is fitted, damper weight must be transferred to new
rear final drive ⇒ page 45 .
Installing:
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
• Tightening torques
⇒ “2.1.1 Exploded view - final drive 0BC, 0BD”, page 45

2. Final drive 67
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– With assistance of 2nd mechanic, bring rear final drive -1- into
installation position on subframe -2-.
– Fit drive shaft (left-side) -arrow 3- into flange shaft of final drive.
– 2nd mechanic must now push rear final drive -1- towards left
side of vehicle in direction of -arrow-.
– Then fit drive shaft (right-side) -5- into flange shaft -4- of final
drive.
– Detach engine and gearbox jack - V.A.G 1383 A- with support
- T10149- from rear left suspension.

– Place engine and gearbox jack - V.A.G 1383 A- with universal

gearbox support - V.A.G 1359/2- and a suitable block of wood
(approx. 80 mm high) below rear final drive -A-.
– Then push final drive -A- slightly forwards.
– Turn cross member -B- towards top left in opposite direction
to -arrow 1- and bring into position, guiding past final drive
-arrow 2-.

– Now tighten 4 bolts securing cross member -B- to rear final

drive in diagonal sequence. Tightening torque
⇒ Item 4 (page 45)
– For this step, guide socket - T40154- through holes in sub‐
frame -A-. If necessary, move final drive slightly to either side.

68 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Screw in bolts -2- and -4- and tighten hand-tight initially.

Note

For illustration purposes the final drive is shown without engine

and gearbox jack - V.A.G 1383 A- and universal gearbox support
- V.A.G 1359/2- .

– Tighten bolt -4-. Tightening torque ⇒ Item 3 (page 45)

– Then tighten bolts -2-. Tightening torque ⇒ Item 2 (page 45)
– Take out engine and gearbox jack - V.A.G 1383 A- from below
final drive.
– Attach drive shafts -1- (left-side) and -3- (right-side) ⇒ Run‐
ning gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing
and installing drive shaft .

– Install heat shield -A- for drive shaft (left-side) on cross mem‐
ber/rear final drive -arrows- ⇒ Item 6 (page 45) .

– Bolt propshaft onto rear final drive ⇒ page 40 .

– Secure centre propshaft bearing to body so it is free of stress.
Tightening torque ⇒ Item 8 (page 23)
– Check gear oil level in rear final drive ⇒ page 107 .

– Secure heat shield -3- to body -arrows-.

– Install rear section of exhaust system and perform stress-free
alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers .
– If originally fitted, install cross member -1- ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view
- underbody trim .
– Fit rear wheel (left-side) and tighten wheel bolts ⇒ Running
gear, axles, steering; Rep. gr. 44 ; Wheels, tyres .

2. Final drive 69
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

2.2.4 Removing and installing final drive 0BD

for Audi A4, A5, Q5
Removing ⇒ page 70
Installing ⇒ page 74
Special tools and workshop equipment required
♦ Counterhold tool - T10172- with adapters - T10172/5-

♦ Socket - T40154-

♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐

box support - V.A.G 1359/2-

Removing:
Refer to general repair instructions ⇒ page 14 .
– Place vehicle on lifting platform.

70 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Note

The flexible pipe connection (de-coupling element) in the front

exhaust pipe must not be bent more than 10° - otherwise it can
be damaged.

– Unfasten clamp(s) -arrows- and disconnect exhaust system.

– Tie front exhaust pipe(s) up to side of underbody.

– If fitted, remove rear cross member -1-.

– Remove rear section of exhaust system -2- ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers; Exploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

Audi A4, Audi A5

– Detach heat shield -3- from body -arrows-.

Continued for all vehicles

– Check whether there is a factory marking (coloured dot)
-arrow A- and -arrow B- on the propshaft and on the propshaft
flange on the rear final drive.
– If one of these markings is no longer visible (for example
-arrow A- on the propshaft), make a new coloured marking
accordingly.
• The markings on the propshaft -arrow A- and on the rear final
drive -arrow B- should be aligned.

– Remove bolts -1- (6x) on rear CV joint.

– Use counterhold tool - T10172- with adapters - T10172/5- .

2. Final drive 71
 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Audi A4, Audi A5

– If removed, re-attach rear cross member -C- to body.
– Place a block of wood -A- (approx. 40 mm high) on rear cross
member -C- to support propshaft -B-.

Note

♦ On the Audi Q5, the propshaft -B- is supported by the heat

shield below the centre bearing.
♦ The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint
or the protective boot can be damaged if the joint is forced
against its stop.

Continued for all vehicles

– Remove bolts -arrows- securing centre propshaft bearing.
– Push propshaft forwards and at the same time pull it off rear
final drive.
– Tie propshaft up to one side on subframe.

– Detach heat shield -A- for drive shaft (left-side) from cross
member/rear final drive -arrows-.

– Unbolt drive shafts on both sides -1- and -3-.

– Slacken off bolts -2- approx. 3 turns.
– Remove bolt -4-.

72 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Place engine and gearbox jack - V.A.G 1383 A- with universal

gearbox support - V.A.G 1359/2- and a suitable block of wood
-A- (approx. 80 mm high) below rear final drive.

Note

Make sure that universal gearbox support - V.A.G 1359/2- does

not make contact with fuel tank.

– Remove bolts -1- (bottom bolts securing cross member to rear

final drive) and -2-.

– Remove 2 top bolts securing cross member -B- to rear final

drive.
– For this step, guide socket - T40154- through holes in sub‐
frame -A-. If necessary, move final drive slightly to either side.

– Then push final drive -A- slightly forwards.

– Turn cross member -B- towards the bottom left -arrow 1-,
guide past final drive -arrow 2- and remove.

Note

A 2nd mechanic is required for the next steps when removing the
rear final drive.

2. Final drive 73
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– 2nd mechanic must now lift right side of rear final drive -1-
slightly and push it towards left side of vehicle in direction of
-arrow-.

Note

The top part of the illustration “I” shows the rear final drive without
engine and gearbox jack - V.A.G 1383 A- and universal gearbox
support - V.A.G 1359/2- .

– Guide drive shaft (right-side) -5- upwards out of flange shaft

(right-side) -4- of rear final drive.
– Then guide out drive shaft (left-side) -3-.

– Secure rear final drive with strap -B-.

A - Block of wood
– Lower rear final drive completely.

Installing:
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Using engine and gearbox jack - V.A.G 1383 A- with universal
gearbox support - V.A.G 1359/2- , bring rear final drive -1- into
position on subframe -2-.

Note

The top part of the illustration “I” shows the rear final drive without
engine and gearbox jack - V.A.G 1383 A- and universal gearbox
support - V.A.G 1359/2- .

– Fit drive shaft (left-side) -arrow 3- into flange shaft of final drive.
– 2nd mechanic must now lift right side of rear final drive -1-
slightly and push it towards left side of vehicle in direction of
-arrow-.
– Then fit drive shaft (right-side) -5- into flange shaft (right-side)
-4- of final drive.

74 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Then push final drive -A- slightly forwards.

– Turn cross member -B- towards top left in opposite direction
to -arrow 1- and bring into position, guiding past final drive
-arrow 2-.

– Tighten 4 bolts securing cross member -B- to rear final drive

in diagonal sequence to specified torque ⇒ Item 4 (page 45) .
– For this step, guide socket - T40154- through holes in sub‐
frame -A-. If necessary, move final drive slightly to either side.

– Screw in bolts -2- and -4- and tighten hand-tight initially.

Note

For illustration purposes the final drive is shown without engine

and gearbox jack - V.A.G 1383 A- and universal gearbox support
- V.A.G 1359/2- .

– Tighten bolt -4- to specified torque ⇒ Item 3 (page 45) .

– Then tighten bolts -2- to specified torque ⇒ Item 2 (page 45) .
– Take out engine and gearbox jack - V.A.G 1383 A- from below
final drive.
– Attach drive shafts -1- (left-side) and -3- (right-side) ⇒ Run‐
ning gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing
and installing drive shaft .

2. Final drive 75
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– Install heat shield -A- for drive shaft (left-side) on cross mem‐
ber/rear final drive -arrows- ⇒ Item 6 (page 45) .

– Bolt propshaft onto rear final drive. Align markings as descri‐

bed and observe tightening sequence ⇒ page 40 .
– Secure centre propshaft bearing to body so it is free of stress
and tighten -arrows-. Tightening torque ⇒ Item 8 (page 23)
– Check gear oil level in rear final drive ⇒ page 108 .

Audi A4, Audi A5

– Secure heat shield -3- to body -arrows-.
Continued for all vehicles
– Install rear section of exhaust system and perform stress-free
alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers .
– If originally fitted, secure cross member -1- to body ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded
view - underbody trim .

2.2.5 Removing and installing final drive 0BF

for Audi A4, A5, A6, A7, Q5
Removing ⇒ page 77
Installing ⇒ page 80
Refer to general repair instructions ⇒ page 14 .
Observe safety precautions ⇒ page 10 .
Special tools and workshop equipment required

76 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐

box support - V.A.G 1359/2-

♦ Tensioning strap - T10038-

♦ Counterhold tool - T10172- with adapters - T10172/5-

Removing:
– Place vehicle on lifting platform.
– Detach wheel trim from rear left wheel (on vehicles with light
alloy wheels, pull off trim cap using puller from vehicle tool kit).
– Remove rear wheels.

Note

The flexible pipe connection (de-coupling element) in the front

exhaust pipe must not be bent more than 10° - otherwise it can
be damaged.

– Unfasten clamps -1- and -2- and disconnect exhaust system.

– Tie front exhaust pipes to side of underbody.

2. Final drive 77
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– If fitted, remove cross member -1- (rear) ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim .
– Remove rear section of exhaust system -2- ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers; Exploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Remove propshaft ⇒ page 24 .

– Detach heat shield -A- for drive shaft (left-side) from rear final
drive -arrows-.

– Unscrew bolts -arrows- and detach bracket -1- from rear final
drive.

Note

Mark connectors -2- for oil pressure and oil temperature senders
and at clutch valves .

– Unplug connectors -2- from oil pressure and oil temperature

senders and clutch valves .
– Then unplug connector -4- from all-wheel drive pump - V415- .
– Subsequently, unclip wiring harness -3- from final drive and
subframe -items 5 ... 7- and tie up.

– Unbolt drive shafts (left -1- and right -3-) from final drive.
– Slacken off bolts -2- approx. 3 turns.
– Remove bolt -4-.

78 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Lower rear section of subframe -1- as follows:

– Unscrew rear bolt (right-side) securing subframe to body.
– Screw spindle - 3346- with nut - 3346/3- and thrust pad from
assembly tool - 3301- into this threaded hole.
– Then unscrew rear bolt (left-side) securing subframe to body.
– Subsequently, lower subframe a distance of -a- = 40 mm.
While doing so, counterhold spindle - 3346- and turn nut -
3346/3- in anti-clockwise direction.

– Place engine and gearbox jack - V.A.G 1383 A- with universal

gearbox support - V.A.G 1359/2- and a suitable rubber mat or
hard-foam slab -A- below rear final drive.

Caution

The rubber mat or hard-foam slab are necessary to prevent

damage to the clutch valves on the rear final drive.
Use tensioning strap - T10038- to secure rear final drive to
prevent it from dropping.

– Unscrew the two rear bolts -2- securing rear final drive to sub‐
frame.
– A 2nd mechanic is required for the next steps when removing
the final drive.

2. Final drive 79
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– 2nd mechanic must now push rear final drive towards right
side of vehicle in direction of -arrow-.
– At the same time, guide drive shaft (left-side) -1- upwards out
of flange shaft -2- of final drive.
– Then guide out drive shaft (right-side) and tilt rear final drive
down towards rear.
– Carefully lower final drive together with 2nd mechanic, paying
attention to subframe.

WARNING

♦ Do not raise or lower vehicle while engine and gearbox

jack - V.A.G 1383 A- is positioned under the vehicle.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle for longer than necessary.

Installing:
Perform installation in reverse sequence of removal. Note the fol‐
lowing:

WARNING

Malfunctions can occur on rear final drive!

Additional work is required if the rear final drive has been re‐
newed ⇒ page 88 .

– Using engine and gearbox jack carefully raise rear final drive
and, working with 2nd mechanic, bring it into installation posi‐
tion on subframe.
-A- = rubber mat or hard-foam slab

Caution

The rubber mat or hard-foam slab are necessary to prevent

damage to the clutch valves on the rear final drive.
Use tensioning strap - T10038- to secure rear final drive to
prevent it from dropping.

– Fit drive shaft (right-side) into flange shaft of final drive.

80 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– 2nd mechanic must now push rear final drive towards right
side of vehicle in direction of -arrow-.
– Then fit drive shaft (left-side) -1- into flange shaft -2- of final
drive.

– Screw in bolts -2- securing rear final drive to subframe (hand-

tight).

Note

For illustration purposes the final drive is shown without engine

and gearbox jack - V.A.G 1383 A- and universal gearbox support
- V.A.G 1359/2- .

– Tighten bolt -4- to specified torque and then tighten bolts -2-
to specified torque ⇒ page 47 .
– Take out engine and gearbox jack - V.A.G 1383 A- from below
final drive.
– Attach drive shafts -1- (left-side) and -3- (right-side) ⇒ Run‐
ning gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing
and installing drive shaft .

Then secure rear section of subframe -1- to body as follows:

– First turn nut - 3346/3- in clockwise direction while counter‐
holding spindle - 3346- until subframe makes contact with
body.
– Then screw in rear bolt (left-side) securing subframe to body
and tighten to specified torque ⇒ Running gear, axles, steer‐
ing; Rep. gr. 42 ; Subframe; Exploded view - subframe .
– Then remove spindle - 3346- , screw in rear bolt (right-side)
securing subframe to body and tighten to specified torque ⇒
Running gear, axles, steering; Rep. gr. 42 ; Subframe; Ex‐
ploded view - subframe .

– Install heat shield -A- for drive shaft (left-side) on rear final
drive -arrows- ⇒ page 47 .

2. Final drive 81
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– Clip in wiring harness -3- at final drive and subframe

-items 5 ... 7-.
– Plug in connectors -4- and -2-, paying attention to marks made
during removal for identification of oil pressure and oil tem‐
perature senders and clutch valves .

Caution

Risk of damage to the wiring harness.

♦ When installing bracket -1- to rear final drive, make sure
wiring harness -3- is not trapped.

– Install bracket -1- at rear final drive

and tighten bolts -arrows- to specified torque ⇒ page 89 .

Note

♦ Allocation of connectors for oil pressure and oil temperature

senders and at clutch valves :
♦ -1- = connector for oil pressure and oil temperature sender 2
- G640-
♦ -2- = connector for oil pressure and oil temperature sender -
G437-
♦ -3- = connector for clutch valve 2 for all-wheel drive - N446-
♦ -4- = connector for clutch valve for all-wheel drive - N445-

– Install propshaft (align markings and observe tightening se‐

quence ⇒ page 40 ).
– Check oil level in rear final drive ⇒ page 108 .
– Check ATF level in rear final drive ⇒ page 116 .
– Install rear section of exhaust system and perform stress-free
alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers .
– If originally fitted, install rear cross member ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view
- underbody trim .
– Fit rear wheels and tighten wheel bolts ⇒ Running gear, axles,
steering; Rep. gr. 44 ; Wheels, tyres .
• Additional work is required if the rear final drive has been re‐
newed ⇒ page 88 .

2.2.6 Removing and installing final drive 0BF

for Audi RS 4, RS 5
Removing ⇒ page 83
Installing ⇒ page 85
Special tools and workshop equipment required

82 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Engine and gearbox jack - V.A.G 1383 A-

Removing:
– Remove rear cross member -1- ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody trim; Exploded view - under‐
body trim .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Remove rear section -2- of exhaust system ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers; Exploded view - silencers .
– Detach propshaft from rear final drive ⇒ page 39 .

– To support propshaft -B-, place a wooden block -A- (approx.

40 mm high) on rear cross member -C-.

Note

The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint or
the protective boot can be damaged if the joint is forced against
its stop.

– Remove bolts -arrows- and detach heat shield -1- for drive
shaft (left-side).
– Unbolt drive shafts (both sides) from rear final drive ⇒ Running
gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing and
installing drive shaft .

2. Final drive 83
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– Remove bolts -arrows- and detach guard plate for electrical

wiring.

– Unplug electrical connectors -1 ... 5- and move wiring harness

clear -arrow-.

– Remove bolt -1- and slacken bolts -2-.

– Place engine and gearbox jack - V.A.G 1383 A- below rear

final drive, with wooden block -A- on support plate of jack, and
take up weight of final drive.

Note

Make sure that the support plate of the engine and gearbox jack
does not come into contact with the fuel tank.

– Remove bolts -arrows-.

84 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Push rear final drive towards the left -arrow A-.

– Lift drive shaft (right-side) -1- clear.
– In order to detach flange shaft (left-side) from drive shaft, lower
rear final drive at right side first -arrow B-.
– Secure rear final drive with a strap and lower final drive further
using engine and gearbox jack - V.A.G 1383 A- .
Installing:
Installation is carried out in reverse sequence; note the following:

WARNING

Malfunctions can occur on rear final drive!

Additional work is required if the rear final drive has been re‐
newed ⇒ page 88 .

• Tightening torques ⇒ page 47

– Secure drive shafts to rear final drive ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Drive shaft; Removing and installing
drive shaft .
– Install propshaft ⇒ page 40 .
– Install exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/silenc‐
ers; Exploded view - silencers and perform stress-free align‐
ment.
– Install rear cross member ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody trim .
– Check ATF level in rear final drive ⇒ page 116 .
– Check gear oil level in rear final drive ⇒ page 108 .
• Additional work is required if the rear final drive has been re‐
newed ⇒ page 88 .

2.2.7 Removing and installing final drive 0BE,

0BF for Audi A8
Removing ⇒ page 86
Installing ⇒ page 88
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A-

2. Final drive 85
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Removing:
– Remove rear cross member -1- ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody trim; Exploded view - under‐
body trim .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Remove rear section -2- of exhaust system ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers; Exploded view - silencers .
– Detach propshaft from rear final drive ⇒ page 39 .

– To support propshaft -B-, place a wooden block -A- (approx.

40 mm high) on rear cross member -C-.

Note

The propshaft can be bent as far as the stop at the centre joint,
but must not be subjected to any kind of force. The centre joint or
the protective boot can be damaged if the joint is forced against
its stop.

– Remove bolts -arrows- and detach heat shield -1- for drive
shaft (left-side).
– Unbolt drive shafts (both sides) from rear final drive ⇒ Running
gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing and
installing drive shaft .

– Unplug electrical connectors -1 ... 5- and move wiring harness

clear -arrow-.

86 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Remove bolt -1- and slacken bolts -2-.

– Place engine and gearbox jack - V.A.G 1383 A- below rear

final drive, with wooden block -A- on support plate of jack, and
take up weight of final drive.

Note

Make sure that the support plate of the engine and gearbox jack
does not come into contact with the fuel tank.

– Remove bolts -arrows-.

2. Final drive 87
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Push rear final drive towards the left -arrow A-.

– Lift drive shaft (right-side) -1- clear.
– In order to detach flange shaft (left-side) from drive shaft, lower
rear final drive at right side first -arrow B-.
– Secure rear final drive with a strap and lower final drive further
using engine and gearbox jack - V.A.G 1383 A- .
Installing:
Installation is carried out in reverse sequence; note the following:

WARNING

Malfunctions can occur on rear final drive!

Additional work is required if the rear final drive has been re‐
newed ⇒ page 88 .

• Tightening torques ⇒ page 47

– Secure drive shafts to rear final drive ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Drive shaft; Removing and installing
drive shaft .
– Install propshaft ⇒ page 40 .
– Install exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/silenc‐
ers; Exploded view - silencers and perform stress-free align‐
ment.
– Install rear cross member ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody trim .
– Check gear oil level in rear final drive ⇒ page 108 .
– Check ATF level in rear final drive ⇒ page 116 .
• Additional work is required if the rear final drive has been re‐
newed ⇒ page 88 .

2.2.8 Additional work required after renewing

final drive 0BE, 0BF

WARNING

Malfunctions can occur on rear final drive!

The following additional work is required if the rear final drive
has been renewed:
♦ Bleeding hydraulic control unit ⇒ Vehicle diagnostic tester
♦ Adapting all-wheel drive control unit - J492- to rear final
drive ⇒ Vehicle diagnostic tester.
• Only perform this additional work if the rear final drive has
been renewed.

Procedure:
– Connect vehicle diagnostic tester and switch on ignition.
– Using vehicle diagnostic tester in Guided Functions mode,
select 22 - Four-wheel electronics and then select the
function 22 - Replace rear final drive .

88 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

• It is important to follow all instructions given by the vehicle di‐

agnostic tester exactly.
Using the vehicle diagnostic tester, the new rear final drive is
“adapted” to the all-wheel drive control unit - J492- .

Note

When 22 - Replacing rear final drive function has been

completed, a system check is performed. Any malfunctions during
this test must be eliminated via the “Guided Fault Finding”.

Tightening torque
Component Nm
Bracket for wiring harness to rear final drive 9

2. Final drive 89
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

3 Dismantling and assembling final

drive

Note

At present there is no provision for dismantling the final drives

0BC and 0BD.

⇒ “3.1 Exploded view - dismantling and assembling final drive”,

page 90
⇒ “3.2 Removing and installing hydraulic control unit”,
page 93
⇒ “3.3 Dismantling and assembling hydraulic control unit”,
page 96
⇒ “3.4 Removing and installing all-wheel drive pump V415 ”, page
99
⇒ “3.5 Removing and installing oil pressure and oil temperature
sender G437 or oil pressure and oil temperature sender 2 G640
”, page 101
⇒ “3.6 Removing and installing clutch valve for all-wheel drive
N445 or clutch valve 2 for all-wheel drive N446 ”, page 104
⇒ “3.7 Checking torque distribution”, page 106

3.1 Exploded view - dismantling and assem‐

bling final drive
⇒ “3.1.1 Exploded view - dismantling and assembling final drive
0BE, 0BF”, page 90

3.1.1 Exploded view - dismantling and assembling final drive 0BE, 0BF

Caution

Only certain parts of the rear final drive may be dismantled.

90 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

1 - Bolt
❑ 50 Nm and then turn
180° further
❑ Always renew
2 - Flange shaft (right-side)
❑ Removing and installing
⇒ page 128
❑ Do not interchange with
flange shaft (left-side);
the two shafts are differ‐
ent
3 - Protective ring
❑ Renewing ⇒ page 158
4 - Protective cap
❑ For Audi A8 only
❑ Retrofit this component
on Audi A8 if not fitted ⇒
Electronic parts cata‐
logue
❑ Installation position
⇒ page 93
5 - ATF breather
❑ For superposition gear
(left-side)
❑ Clip onto breather pipe
6 - Gasket
❑ With strainer
7 - Hydraulic control unit
❑ With all-wheel drive
pump - V415- and pipes
to superposition gears
❑ Removing and installing
⇒ page 93
❑ Dismantling and assembling ⇒ page 96
8 - Bolt
❑ 20 Nm
❑ 2x
❑ M8, 50 mm long
❑ Follow correct tightening sequence ⇒ page 95
9 - Bolt
❑ 20 Nm
❑ M8, 50 mm long
❑ With captive seal underneath bolt head
❑ Coat thread with sealing paste - D 176 501 A1-
❑ Follow correct tightening sequence ⇒ page 95
10 - Bolt
❑ 20 Nm
❑ M8, 30 mm long
❑ Follow correct tightening sequence ⇒ page 95
11 - Oil seal
❑ For flange shaft (left-side)

3. Dismantling and assembling final drive 91

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

❑ Renewing ⇒ page 128

12 - Superposition gear (left-side)
13 - ATF inspection plug
❑ 15 Nm
❑ Always renew
❑ With captive seal
14 - Flange shaft (left-side)
❑ Removing and installing ⇒ page 128
❑ Do not interchange with flange shaft (right-side); the two shafts are different
15 - Protective ring
❑ Renewing ⇒ page 158
16 - ATF drain plug
❑ 15 Nm
❑ Always renew
❑ With captive seal
17 - Drain plug for gear oil
❑ 15 Nm
❑ Always renew
❑ With captive seal
18 - Final drive housing
19 - Oil seal
❑ For propshaft flange
❑ Renewing (final drive 0BF) ⇒ page 147
❑ Renewing (final drive 0BE) ⇒ page 142
20 - Protective ring
❑ Renewing ⇒ page 164
21 - Propshaft flange
❑ Removing and installing (final drive 0BF) ⇒ page 147
❑ Removing and installing (final drive 0BE) ⇒ page 142
22 - Circlip
❑ Always renew
❑ Installing (final drive 0BF) ⇒ page 154
❑ Installing (final drive 0BE) ⇒ page 147
23 - Gear oil inspection plug
❑ 15 Nm
❑ Always renew
❑ With captive seal
24 - Bracket
❑ For wiring harness
25 - Bolt
❑ 9 Nm
26 - Superposition gear (right-side)
27 - Oil seal
❑ For flange shaft (right-side)
❑ Renewing ⇒ page 128

92 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

28 - ATF breather
❑ For superposition gear (right-side)
❑ Clip onto breather pipe
29 - Breather for final drive
❑ Clip onto breather pipe

Installation position of protective cap (for Audi A8 only)

– Protective cap -A- is clipped into groove behind ATF breather
pipe -B-.

Note

The protective cap must be fitted on both sides of the ATF breath‐
er pipe.

3.2 Removing and installing hydraulic con‐

trol unit
⇒ “3.2.1 Removing and installing hydraulic control unit, 0BE,
0BF”, page 93

3.2.1 Removing and installing hydraulic con‐

trol unit, 0BE, 0BF

Note

♦ Refer to general repair instructions ⇒ page 14 .

♦ Observe safety precautions ⇒ page 10 .

Removing
• Ignition is switched off.
– Place vehicle on lifting platform.
– Lower rear section of exhaust system slightly and secure; if
necessary remove rear section of exhaust system ⇒ Rep. gr.
26 ; Exhaust pipes/silencers; Exploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

3. Dismantling and assembling final drive 93

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– If fitted, unscrew bolts -arrows- and detach bracket -1- for wir‐
ing harness from rear final drive.

Note

Mark connectors -2- for oil pressure and oil temperature senders
and clutch valves .

– Unplug connectors -2- from oil pressure and oil temperature

senders and clutch valves .
– Then unplug connector -4- from all-wheel drive pump - V415- .
– Subsequently, unclip wiring harness -3- from final drive and
subframe -items 5 ... 7- and tie up.
– Position drip tray under rear final drive.
– Drain ATF from rear final drive ⇒ page 117 .
– Drain gear oil from rear final drive ⇒ page 109 .
– Remove all-wheel drive pump - V415- ⇒ page 99 .

Note

To loosen and tighten the nut for the pipe (right-side) at the hy‐
draulic control unit ⇒ page 94 , the all-wheel drive pump - V415-
must be removed.

– Loosen pipe (left-side) -6- and pipe (right-side) -7- leading to

hydraulic control unit -1- one turn -arrows A- and disconnect
from superposition gears -arrows B-.
– Unscrew bolts -2 ... 5- and detach hydraulic control unit -1- with
gasket.

94 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Installing

Note

Carefully observe safety precautions when renewing hydraulic

control unit. If possible the “old” senders must be re-installed
⇒ page 14 .

Requirements:
• Renew gasket between hydraulic control unit -1- and final
drive housing
• Centring pins ⇒ Item 18 (page 98) must be installed in hous‐
ing of hydraulic control unit.
• To attach hydraulic control unit -1- to rear final drive, pipes (left
-6- and right -7-) must be screwed into control unit loosely.
Attach hydraulic control unit -1- to rear final drive as follows:
First screw pipe connections -6- and -7- hand-tight into super‐
position gears -arrows B-.
Then screw in bolts -2 ... 5- hand-tight (bolt -2- is fitted with a
captive seal underneath the bolt head; coat the thread of this
bolt with sealing paste - D 176 501 A1- ).
Tighten bolts -2 ... 5- to specified torque in the sequence -4-,
-2-, -5- and -3- (M8 x 30 mm).
Then tighten nuts -arrows A- and -arrows B- at pipes (left -6-
and right -7-) to specified torque.
– Install all-wheel drive pump - V415- ⇒ page 99 .

– Clip in wiring harness -3- at final drive and subframe

-items 5 ... 7-.
– Plug in connectors -4- and -2-, paying attention to marks made
during removal for identification of oil pressure and oil tem‐
perature senders and clutch valves .
– If fitted, install bracket -1- for wiring harness at rear final drive
and tighten bolts -arrows- to specified torque. Take care not
to trap wiring harness -3-.

3. Dismantling and assembling final drive 95

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Note

♦ Allocation of connectors for oil pressure and oil temperature

senders and at clutch valves :
♦ -1- = connector for oil pressure and oil temperature sender 2
- G640-
♦ -2- = connector for oil pressure and oil temperature sender -
G437-
♦ -3- = connector for clutch valve 2 for all-wheel drive - N446-
♦ -4- = connector for clutch valve for all-wheel drive - N445-

– Fill up gear oil in rear final drive and check oil level
⇒ page 108 .
– Fill up ATF in rear final drive and check ATF level
⇒ page 116 .
– Install rear section of exhaust system and perform stress-free
alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers .

3.3 Dismantling and assembling hydraulic

control unit
⇒ “3.3.1 Dismantling and assembling hydraulic control unit, 0BE,
0BF”, page 96

3.3.1 Dismantling and assembling hydraulic control unit, 0BE, 0BF

96 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

1 - Bolt
❑ 5 Nm
2 - All-wheel drive pump -
V415-
❑ Removing and installing
⇒ page 99
3 - O-ring
❑ Always renew
4 - Adapter

Note

♦ Adapter can fall out during re‐

moval of all-wheel drive pump -
V415-
♦ Before installing all-wheel drive
pump - V415- , insert adapter in
recesses in hydraulic pump

5 - Hydraulic pump
❑ Consists of guide ring,
housing and 6 pistons
❑ Assembling
⇒ page 99
6 - Ball bearing
❑ Can be removed and in‐
stalled by hand
7 - Pipe (left-side)
❑ Tighten nuts to 30 Nm
❑ Installed between hy‐
draulic control unit and
superposition gear (left-
side)
❑ When installing, first screw in both nuts hand-tight
8 - O-ring
❑ Always renew
9 - Oil pressure and oil temperature sender - G437-
❑ 10 Nm
❑ Brown connection
❑ Removing and installing ⇒ page 101
10 - Oil pressure and oil temperature sender 2 - G640-
❑ 10 Nm
❑ Black connection
❑ Removing and installing ⇒ page 101
11 - Clutch valve 2 for all-wheel drive - N446-
❑ Colour: brown
❑ Removing and installing ⇒ page 104
❑ Installation position: connector must face upwards towards oil pressure and oil temperature sender

3. Dismantling and assembling final drive 97

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Caution
Do not interchange with
clutch valve for all-wheel
drive - N445- .

12 - Clutch valve for all-wheel drive - N445-

❑ Colour: black
❑ Removing and installing ⇒ page 104
❑ Installation position: connector must face upwards towards oil pressure and oil temperature sender

Caution
Do not interchange with
clutch valve 2 for all-
wheel drive - N446- .

13 - Bolt
❑ 2.5 Nm
14 - O-ring
❑ Always renew
❑ Fit on clutch valve
15 - Spring
❑ Insert in guide ⇒ Item 16 (page 98)
16 - Guide
❑ Installation position: large diameter must face ball ⇒ Item 17 (page 98)
17 - Ball
❑ Before installing, insert in guide ⇒ Item 16 (page 98)
18 - Housing for hydraulic control unit
❑ With centring pins -arrows-
❑ Centring pins lock hydraulic control unit with gasket on final drive housing
19 - Ball
❑ Before installing, insert in hole in shuttle valve ⇒ Item 21 (page 98)
20 - O-ring
❑ Always renew
21 - Shuttle valve
❑ 8 Nm
❑ Removing and installing ⇒ page 99
22 - Gasket
❑ With strainer
❑ Position on centring pins of housing for hydraulic control unit
23 - Pipe (right-side)
❑ Tighten nuts to 30 Nm
❑ Installed between hydraulic control unit and superposition gear (right-side)
❑ When installing, first screw in both nuts hand-tight

98 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Assembling hydraulic pump

– Insert the 6 pistons -A- into housing -B-.
– Then position guide ring -C- so that pistons make contact with
shoulder -arrow-.

– Fit hydraulic pump -1- with guide ring -2- in housing for hy‐
draulic control unit.
Function test:
– Rotate hydraulic pump -1- several times. Check the following:
♦ The hydraulic pump must turn smoothly without sticking or
catching.
♦ All pistons must move in and out.

Removing and installing shuttle valves

Note

First remove all-wheel drive pump - V415- , hydraulic pump and

ball bearing ⇒ Item 6 (page 97) .

– Unscrew shuttle valves -A- (it is important to also remove ball

-C-).
– To install, insert ball in hole in shuttle valve.
– Then carefully screw in shuttle valve with new O-ring -B- as
far as stop.
• The shuttle valve must be below the surface of the housing
-arrow-. If this is not the case, remove the valve and position
the ball correctly.
– Tighten shuttle valve to specified torque
⇒ Item 21 (page 98) .

3.4 Removing and installing all-wheel drive

pump - V415-
⇒ “3.4.1 Removing and installing all-wheel drive pump V415 ,
0BE, 0BF”, page 99

3.4.1 Removing and installing all-wheel drive

pump - V415- , 0BE, 0BF
Special tools and workshop equipment required

3. Dismantling and assembling final drive 99

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Allen key - T10058-

Note

♦ Refer to general repair instructions ⇒ page 14 .

♦ Observe safety precautions ⇒ page 10 .

Removing
– Place vehicle on lifting platform.
• Ignition is switched off.
– Position drip tray under rear final drive.
– Unplug connector -1- from all-wheel drive pump - V415- -2-.
– Unscrew the four bolts securing all-wheel drive pump - V415-
to hydraulic control unit using Allen key - T10058- .
– Carefully detach all-wheel drive pump - V415- -2-; pay atten‐
tion to adapter ⇒ Item 4 (page 97) in hydraulic pump.

Note

♦ Adapter can fall out during removal of all-wheel drive pump -

V415- .
♦ Before installing all-wheel drive pump - V415- , insert adapter
in recesses in hydraulic pump.

Installing
• Hydraulic pump -A- is fitted in installation position in hydraulic
control unit; assembling hydraulic pump ⇒ page 99 .
• Adapter -B- is fitted in recesses in hydraulic pump.
• A new O-ring -D- is fitted on all-wheel drive pump - V415- .
– Insert all-wheel drive pump - V415- with actuating pin -C- in
adapter -B-.

100 Rep. gr.39 - Final drive - rear differential

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– Tighten the four bolts securing all-wheel drive pump - V415-

-2- to specified torque in diagonal sequence
⇒ Item 1 (page 97) .
– Attach connector -1- to all-wheel drive pump - V415- .
– Top up ATF in rear final drive ⇒ page 118 .

3.5 Removing and installing oil pressure

and oil temperature sender - G437- or oil
pressure and oil temperature sender 2 -
G640-
⇒ “3.5.1 Removing and installing oil pressure and oil temperature
sender G437 or oil pressure and oil temperature sender 2 G640 ,
0BE, 0BF”, page 101

3.5.1 Removing and installing oil pressure

and oil temperature sender - G437- or oil
pressure and oil temperature sender 2 -
G640- , 0BE, 0BF
Special tools and workshop equipment required
♦ Socket (27 mm) - T40218-

♦ Vehicle diagnostic tester

Important safety precautions:
♦ After renewing the oil pressure and oil temperature sender -
G437- or the oil pressure and oil temperature sender 2 -
G640- , the identity of the corresponding sender must be re-
adapted in the all-wheel drive control unit - J492- ⇒ Vehicle
diagnostic tester.
♦ Do not renew both oil pressure and oil temperature senders
( -G437- and -G640- ) at the same time, as at least one valid
sender identity is required at any time for the allocation of the
rear final drive to the all-wheel drive control unit - J492- . If both
senders are renewed at the same time, the all-wheel drive
control unit - J492- would interpret this as the replacement of
the rear final drive. This would erase all the learnt values in the
control unit and impair the performance of the rear final drive.
♦ If both oil pressure and oil temperature senders ( -G437- and
-G640- ) have to be renewed due to mechanical damage, e.g.
damage to the connector housing, this should be done in two

3. Dismantling and assembling final drive 101

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steps: After the first sender has been renewed, the identity of
the sender must be re-adapted in the all-wheel drive control
unit - J492- ⇒ Vehicle diagnostic tester. Proceed in the same
manner for the second sender.
♦ If both oil pressure and oil temperature senders ( -G437- and
-G640- have to be renewed due to an electrical fault, the clutch
classification must be entered again in the all-wheel drive con‐
trol unit - J492- ⇒ Vehicle diagnostic tester. In addition, the
ATF in the rear final drive must be renewed ⇒ page 117 .

Note

♦ Refer to general repair instructions ⇒ page 14 .

♦ Observe safety precautions ⇒ page 10 .

Removing
• Ignition is switched off.
– Place vehicle on lifting platform.
– Lower rear section of exhaust system slightly and secure.
– If necessary, remove bracket for wiring harness from rear final
drive ⇒ page 94 .
– Unplug connector -1- from oil pressure and oil temperature
sender 2 - G640- / connector -2- from oil pressure and oil tem‐
perature sender - G437- .

Note

If necessary, unplug connectors -3- and -4-.

– Position drip tray under rear final drive.

– Remove corresponding sender using socket - T40218- .

-A- = oil pressure and oil temperature sender 2 - G640- - black
connection
-B- = oil pressure and oil temperature sender - G437- - brown
connection

102 Rep. gr.39 - Final drive - rear differential

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Installing
– Carefully screw in new sender with new O-ring -arrow- at its
fitting location and tighten to specified torque
⇒ Item 9 (page 97) or ⇒ Item 10 (page 97) .
-A- = oil pressure and oil temperature sender 2 - G640- - black
connection
-B- = oil pressure and oil temperature sender - G437- - brown
connection

– Plug in connector -1- at oil pressure and oil temperature send‐

er 2 - G640- / connector -2- at oil pressure and oil temperature
sender - G437- .

Note

If unplugged earlier, plug in connectors -3- and -4-.

– If removed earlier, install bracket for wiring harness at rear final

drive ⇒ page 82 .
– Connect vehicle diagnostic tester and switch on ignition.
– Using vehicle diagnostic tester in Guided Functions mode,
select 22 - Four-wheel electronics and then select the
function 22 - Adapt sender .
• It is important to follow all instructions given by the vehicle di‐
agnostic tester exactly.
Using the vehicle diagnostic tester, the new sender is “adapted”
to the all-wheel drive control unit - J492- .

Note

When 22 - Adapt sender function has been completed, a sys‐

tem check is performed. Any malfunctions during this test must
be eliminated via the “Guided Fault Finding”.

– Top up ATF in rear final drive ⇒ page 118 .

– Attach rear section of exhaust system to body and perform
stress-free alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers;
Exploded view - silencers .

3. Dismantling and assembling final drive 103

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
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3.6 Removing and installing clutch valve for

all-wheel drive - N445- or clutch valve 2
for all-wheel drive - N446-
⇒ “3.6.1 Removing and installing clutch valve for all-wheel drive
N445 or clutch valve 2 for all-wheel drive N446 , 0BE, 0BF”, page
104

3.6.1 Removing and installing clutch valve for

all-wheel drive - N445- or clutch valve 2
for all-wheel drive - N446- , 0BE, 0BF
Special tools and workshop equipment required
♦ Socket (4 mm) - T10370-

Note

♦ Refer to general repair instructions ⇒ page 14 .

♦ Observe safety precautions ⇒ page 10 .

Caution

Malfunctions on rear final drive.

• Do NOT interchange fitting location of clutch valve for all-
wheel drive - N445- with fitting location of clutch valve 2
for all-wheel drive - N446- .

Removing
• Ignition is switched off.
– Place vehicle on lifting platform.
– Lower rear section of exhaust system slightly and secure.
– Remove bracket for wiring harness from rear final drive
⇒ page 94 .

104 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Note

♦ Mark connectors -1 ... 4- for oil pressure and oil temperature

senders and clutch valves .
♦ Unplug connectors -1- and -2-.

– Unplug connector -3- from clutch valve 2 for all-wheel drive -

N446- / connector -4- from clutch valve for all-wheel drive -
N445- .
– Position drip tray under rear final drive.

– Unscrew bolts -1- of corresponding clutch valve using 4 mm

socket - T10370-
– Carefully prise out clutch valve e.g. using a flat screwdriver;
observe spring -3-. Spring can fall out of opening in hydraulic
control unit -6-.
-A- = clutch valve 2 for all-wheel drive - N446- , brown colour
coding
-B- = clutch valve for all-wheel drive - N445- , black colour
coding

Installing
• Ball -5-, guide -4- (small diameter facing spring) and spring
-3- must be installed in opening in housing -6- for clutch valve
-2-.
– Install new clutch valve with new O-rings -arrows- (coat O-
rings with ATF).
– Pre-tighten bolts -1- evenly hand-tight until they make contact.
Then tighten to specified torque ⇒ Item 13 (page 98) .
Perform remaining installation operations in reverse order of re‐
moval. Note the following:

3. Dismantling and assembling final drive 105

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Note

♦ Allocation of connectors for oil pressure and oil temperature

senders and at clutch valves :
♦ -1- = connector for oil pressure and oil temperature sender 2
- G640-
♦ -2- = connector for oil pressure and oil temperature sender -
G437-
♦ -3- = connector for clutch valve 2 for all-wheel drive - N446-
♦ -4- = connector for clutch valve for all-wheel drive - N445-

– Attach bracket for wiring harness to rear final drive

⇒ page 82 .
– Top up ATF in rear final drive ⇒ page 118 .
– Attach rear section of exhaust system to body and perform
stress-free alignment ⇒ Rep. gr. 26 ; Exhaust pipes/silencers;
Exploded view - silencers .

3.7 Checking torque distribution

⇒ “3.7.1 Checking torque distribution, 0BE, 0BF”, page 106

3.7.1 Checking torque distribution, 0BE, 0BF

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Procedure:

Note

♦ Refer to general repair instructions ⇒ page 14 .

♦ Observe safety precautions ⇒ page 10 .

The function 22 - Check torque distribution must be per‐

formed after the following operations:
♦ Work on wiring of rear final drive
♦ Work on valves: clutch valve for all-wheel drive - N445- and
clutch valve 2 for all-wheel drive - N446-
♦ Work on hydraulic control unit
– Raise vehicle on a platform until wheels no longer make con‐
tact with the floor.
– Connect vehicle diagnostic tester and switch on ignition.
– Using vehicle diagnostic tester in Guided Functions mode,
select 22 - Four-wheel electronics and then select the
function 22 - Check torque displacement (torque dis-
tribution) .

• It is important to follow all instructions given by the vehicle di‐

agnostic tester exactly.
The vehicle diagnostic tester is used to check whether the torque
is directed to the correct side when the rear final drive is activated.

106 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

4 Gear oil
⇒ “4.1 Overview - drain and inspection plugs”, page 107
⇒ “4.2 Checking gear oil level”, page 107
⇒ “4.3 Draining and filling gear oil”, page 109

4.1 Overview - drain and inspection plugs

⇒ “4.1.1 Overview - drain and inspection plugs, 0BE, 0BF”, page
107

4.1.1 Overview - drain and inspection plugs,

0BE, 0BF
Screw plugs for gear oil in rear final drive 0BF
1 - Gear oil inspection plug
♦ Tightening torque ⇒ Item 23 (page 92)
♦ Always renew
2 - Gear oil drain plug
♦ Tightening torque ⇒ Item 17 (page 92)
♦ Always renew

Screw plugs for gear oil in rear final drive 0BE

1 - Gear oil inspection plug
♦ Tightening torque ⇒ Item 23 (page 92)
♦ Always renew
2 - Gear oil drain plug
♦ Tightening torque ⇒ Item 17 (page 92)
♦ Always renew

4.2 Checking gear oil level

⇒ “4.2.1 Checking gear oil level, 0BC”, page 107
⇒ “4.2.2 Checking gear oil level, 0BD”, page 108
⇒ “4.2.3 Checking gear oil level, 0BE, 0BF”, page 108

4.2.1 Checking gear oil level, 0BC

Special tools and workshop equipment required
♦ Drip tray

4. Gear oil 107

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Remove inspection plug -arrow- to check gear oil.

The oil level is correct when the rear final drive is filled to the
bottom lip of the filler hole.
• For gear oil specification, refer to ⇒ Electronic parts cata‐
logue .
– Screw in plug -arrow- and tighten.
Tightening torque: 30 Nm

4.2.2 Checking gear oil level, 0BD

Special tools and workshop equipment required
♦ Drip tray
– Remove inspection plug -arrow- to check gear oil.
The oil level is correct when the rear final drive is filled to the
bottom lip of the filler hole.
• For gear oil specification, refer to ⇒ Electronic parts cata‐
logue .
– Screw in plug -arrow- and tighten.
Tightening torque: 45 Nm

4.2.3 Checking gear oil level, 0BE, 0BF

Test condition:
• Gear oil temperature: 10°C ... 60°C
• Rear final drive must be in installation position.
• Vehicle must be level (horizontal).
• Overview of plugs for gear oil ⇒ page 107
Special tools and workshop equipment required
♦ Drip tray

108 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Rear final drive 0BF

– Remove gear oil inspection plug -arrow- (located on right side
of final drive).

Rear final drive 0BE

– Remove gear oil inspection plug -1-.
Continued for all rear final drive versions
• The oil level is correct when the rear final drive is filled to the
bottom lip of the filler hole.
• For gear oil specification, refer to ⇒ Electronic parts cata‐
logue .
– Top up gear oil if necessary.
♦ ⇒ page 111
♦ ⇒ page 113
– Screw in and tighten gear oil inspection plug -arrow-. Tighten‐
ing torque ⇒ Item 23 (page 92)

4.3 Draining and filling gear oil

⇒ “4.3.1 Draining gear oil, 0BE, 0BF”, page 109
⇒ “4.3.2 Filling up gear oil, 0BE”, page 111
⇒ “4.3.3 Filling up gear oil, 0BF”, page 113

4.3.1 Draining gear oil, 0BE, 0BF

Special tools and workshop equipment required
♦ Drip tray

4. Gear oil 109

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Rear final drive 0BF

– Remove gear oil inspection plug -arrow-.

Note

♦ Overview of plugs for gear oil ⇒ page 107

♦ The gear oil drains out of the drain hole faster if the inspection
plug is removed.

– Remove gear oil drain plug -arrow- and drain off gear oil.

Rear final drive 0BE

– Remove gear oil inspection plug -1-.

Note

♦ Overview of plugs for gear oil ⇒ page 107

♦ The gear oil drains out of the drain hole faster if the inspection
plug is removed.

– Remove gear oil drain plug -arrow- and drain off gear oil.
Continued for all rear final drive versions
– Screw in and tighten new gear oil drain plug -arrow-. Tighten‐
ing torque ⇒ Item 17 (page 92)
♦ ⇒ “4.3.2 Filling up gear oil, 0BE”, page 111
♦ ⇒ “4.3.3 Filling up gear oil, 0BF”, page 113

110 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
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4.3.2 Filling up gear oil, 0BE

Special tools and workshop equipment required
♦ Charging device for Haldex coupling 2 - VAS 6291- or -VAS
6291A-

♦ Adapter for oil filling - VAS 6291/2- or -VAS 6291/3-

♦ Drip tray
• Rear final drive must be in installation position.
• Vehicle must be level (horizontal).
• Overview of plugs for gear oil ⇒ page 107
• Gear oil drain plug must be fitted and tightened. Tightening
torque ⇒ Item 17 (page 92)
• For oil specification, refer to ⇒ Electronic parts catalogue .
– For topping up, use charging device - VAS 6291- .
– Raise vehicle.
– Remove gear oil inspection plug -1-.

– Screw in adapter for oil filling - VAS 6291/1- or -VAS 6291/2-

-1-.

4. Gear oil 111

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Connect elbow joint -A- and adapter -B-, making sure they en‐
gage.
– Route hose above drive shaft (right-side).
• The hose must not hang down. It must emerge above rear
wheel on right side of vehicle.
– Lower vehicle.

– Please make sure that valve -arrow- is closed.

– Screw oil container -A- onto charging device - VAS 6291- .
– Now open valve -arrow- and hold oil container as shown in
illustration.
The rear final drive will now be filled.

• The rear final drive is filled correctly when oil comes out be‐
tween the adapter -B- and the rear final drive housing.
– Raise vehicle.
– When oil has started to emerge at adapter -B-, place oil res‐
ervoir e.g. onto a workshop trolley.
Part of the excess oil will now flow back into the oil reservoir.
– Remove charging device - VAS 6291- as soon as oil stops
flowing back into the reservoir.
• The oil level is correct when the rear final drive is filled to the
bottom lip of the filler hole.
– Top up gear oil again if necessary.

– Screw in new plug -1- and tighten. Tightening torque

⇒ Item 23 (page 92) .

112 Rep. gr.39 - Final drive - rear differential

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4.3.3 Filling up gear oil, 0BF

Special tools and work‐
shop equipment re‐
quired
♦ Charging device for
Haldex coupling 2 -
VAS 6291- or -VAS
6291A-

♦ Adapter for oil filling -

VAS 6291/3- (rework
if necessary
⇒ page 113 )

♦ Drip tray
Depending on version,
the spacer tube of the
adapter for oil filling -
VAS 6291/3- may make
contact with a housing
rib on the final drive.
– File down the spacer
tube of the adapter
opposite the two
holes on the side
-arrows-, as shown in
illustration.
Filling up gear oil
• Rear final drive must
be in installation posi‐
tion.
• Vehicle must be level
(horizontal).
• Overview of plugs for
gear oil ⇒ page 107
• Gear oil drain plug
must be fitted and
tightened. Tightening
torque
⇒ Item 17 (page 92)

4. Gear oil 113

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

• For oil specification,

refer to ⇒ Electronic
parts catalogue .

– Raise vehicle.
– Remove gear oil inspection plug -arrow-.

– Disconnect adapter -A- and elbow joint -B-.

– Screw adapter -A- in onto stop.

Caution

Risk of damage to thread of oil filler hole.

• Do not screw adapter -A- in at an angle.
• The filed down side of adapter -A- must point towards
housing rib -arrow-.

– Connect elbow joint -B- and adapter -A-, making sure they en‐
gage.
– Route hose above drive shaft (right-side).
• The hose must not hang down. It must emerge above rear
wheel on right side of vehicle.
– Lower vehicle.

– Please make sure that valve -arrow- is closed.

– Screw oil container -A- onto charging device - VAS 6291- .
– Now open valve -arrow- and hold oil container as shown in
illustration.
The rear final drive will now be filled.

114 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

• The rear final drive is filled correctly when oil comes out be‐
tween the adapter -A- and the rear final drive housing
-arrow-.
– Raise vehicle.
– If oil has started to emerge at adapter -A-, place oil reservoir
e.g. onto a workshop trolley.
Part of the excess oil will now flow back into the oil reservoir.
– Remove charging device - VAS 6291- as soon as oil stops
flowing back into the reservoir.
• The oil level is correct when the rear final drive is filled to the
bottom lip of the filler hole.
– Top up gear oil again if necessary.

– Screw in and tighten new gear oil inspection plug -arrow-.

Tightening torque ⇒ Item 23 (page 92)

4. Gear oil 115

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5 ATF
⇒ “5.1 Overview - drain and inspection plugs”, page 116
⇒ “5.2 Checking ATF level”, page 116
⇒ “5.3 Draining and filling ATF”, page 117

5.1 Overview - drain and inspection plugs

⇒ “5.1.1 Overview - drain and inspection plugs, 0BE”, page 116
⇒ “5.1.2 Overview - drain and inspection plugs, 0BF”, page 116

5.1.1 Overview - drain and inspection plugs,

0BE
1 - ATF inspection plug
♦ Identification: »ATF« on final drive housing -arrow-
♦ Tightening torque ⇒ Item 13 (page 92)
♦ Always renew
2 - ATF drain plug
♦ Tightening torque ⇒ Item 16 (page 92)
♦ Always renew

5.1.2 Overview - drain and inspection plugs,

0BF
1 - ATF inspection plug
♦ Identification: »ATF« on housing -arrow-
♦ Tightening torque ⇒ Item 13 (page 92)
♦ Always renew
2 - ATF drain plug
♦ Tightening torque ⇒ Item 16 (page 92)
♦ Always renew

5.2 Checking ATF level

⇒ “5.2.1 Checking ATF level, 0BE, 0BF”, page 116

5.2.1 Checking ATF level, 0BE, 0BF

Test condition:
• ATF temperature 10°C ... 60°C
• Rear final drive must be in installation position.
• Vehicle must be level (horizontal).
Special tools and workshop equipment required
♦ Drip tray

116 Rep. gr.39 - Final drive - rear differential

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– Unscrew ATF inspection plug -1- to check ATF level.

Caution

♦ The inspection plug -1- for checking the ATF level is lo‐
cated on the left side of the rear final drive. Identification:
»ATF« on final drive housing -arrow-.
♦ Overview of plugs for ATF ⇒ page 116

• The ATF level is correct when the rear final drive is filled to the
bottom lip of the filler hole.
If ATF level is correct:
– Screw in and tighten new ATF inspection plug. Tightening tor‐
que ⇒ Item 13 (page 92)
If ATF level is not correct:
– Top up with ATF ⇒ page 118 .

5.3 Draining and filling ATF

⇒ “5.3.1 Draining ATF, 0BE”, page 117
⇒ “5.3.2 Draining ATF, 0BF”, page 117
⇒ “5.3.3 Filling up ATF, 0BE, 0BF”, page 118

5.3.1 Draining ATF, 0BE

Special tools and workshop equipment required
♦ Drip tray
• Overview of plugs for ATF ⇒ page 116
– Remove ATF inspection plug -1- so that ATF drains faster from
drain hole.
– Remove ATF drain plug -2- and drain off ATF.
– Screw in and tighten new ATF drain plug -2-. Tightening torque
⇒ Item 16 (page 92)
– Fill up ATF in rear final drive ⇒ page 118 .

5.3.2 Draining ATF, 0BF

Special tools and workshop equipment required
♦ Drip tray
• Overview of plugs for ATF ⇒ page 116

5. ATF 117
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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Remove ATF inspection plug -arrow- so that ATF drains from

drain hole faster.

– Remove ATF drain plug -arrow- and drain off ATF.

– Screw in and tighten new ATF drain plug -arrow-. Tightening
torque ⇒ Item 16 (page 92)
– Fill up ATF in rear final drive ⇒ page 118 .

5.3.3 Filling up ATF, 0BE, 0BF

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
♦ Charging device for Haldex coupling 2 - VAS 6291- or -VAS
6291A-

♦ Adapter for oil filling - VAS 6291/3-

♦ Drip tray

118 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Test conditions:
• Rear final drive must be in installation position.
• Vehicle must be level (horizontal).
• ATF drain plug must be inserted and tightened. Tightening
torque ⇒ Item 16 (page 92)

Caution

Risk of damage to rear final drive.

♦ Use only the ATF available as a replacement part ⇒ Elec‐
tronic parts catalogue .
♦ Other lubricants will cause malfunctions and/or failure of
the final drive.
♦ Select correct type ⇒ Electronic parts catalogue .
♦ The ATF charging device must be clean and the ATF must
not be mixed with other types of oil!

– For topping up, use charging device - VAS 6291- .

– Raise vehicle.
– Unscrew ATF inspection plug -1-.

Caution

The inspection plug -1- for checking the ATF level is located
on the left side of the rear final drive. Identification: »ATF« on
final drive housing -arrow-.

– Disconnect adapter -A- and elbow joint -B-.

– Screw adapter -A- in onto stop.
– Connect elbow joint -B- and adapter -A-, making sure they en‐
gage.
– Route hose above drive shaft (left-side).
• The hose must not hang down. It must emerge above rear
wheel on left side of vehicle.
– Lower vehicle.

5. ATF 119
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– Please make sure that valve -arrow- is closed.

– Screw oil container -A- onto charging device - VAS 6291- .
– Now open valve -arrow- and hold oil container as shown in
illustration.
The hydraulic control unit and the superposition gears (left and
right) in the rear final drive will now be filled.

• The hydraulic control unit for the rear final drive is filled cor‐
rectly when ATF starts to come out at adapter -A-.
If no ATF has emerged at adapter -A-:
– Continue with filling procedure until fluid level is correct.
If ATF has emerged at adapter -A-:
– Raise vehicle.
– Place reservoir e.g. onto a workshop trolley.
Part of the excess oil will now flow back into the oil reservoir.
– Remove charging device - VAS 6291- as soon as ATF stops
flowing back into the reservoir.
• The oil level is correct when the rear final drive is filled to the
bottom lip of the filler hole.

120 Rep. gr.39 - Final drive - rear differential

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– Screw in ATF inspection plug -arrow- hand-tight.

– Connect vehicle diagnostic tester and switch on ignition.
– Using vehicle diagnostic tester in Guided Functions mode,
select 22 - Four-wheel electronics and then select the
function 22 - Adding ATF .
• It is important to follow all instructions given by the vehicle di‐
agnostic tester exactly.
Use vehicle diagnostic tester to fill and vent air from the system.

Note

If the system detects that there is still air in the system after the
function 22 - Adding ATF has been performed, the filling proc‐
ess must be repeated.

– Unscrew ATF inspection plug -arrow- once again.

Test condition:
• The ATF level is correct when the rear final drive is filled to the
bottom lip of the filler hole -arrow-.
• Top up ATF if necessary.
• No entries (either static or sporadic) stored in event memory
⇒ Vehicle diagnostic tester.
– Screw in and tighten new ATF inspection plug -arrow-. Tight‐
ening torque ⇒ Item 13 (page 92) .

5. ATF 121
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6 Oil seals
⇒ “6.1 Overview of fitting locations - oil seals”, page 122
⇒ “6.2 Renewing oil seal (left-side)”, page 123
⇒ “6.3 Renewing oil seal (right-side)”, page 130
⇒ “6.5 Renewing protective ring on flange shaft”, page 154
⇒ “6.6 Renewing protective ring on input shaft flange”,
page 161

6.1 Overview of fitting locations - oil seals

⇒ “6.1.1 Overview of fitting locations - oil seals, 0BC, 0BD”, page
122
⇒ “6.1.2 Overview of fitting locations - oil seals, 0BE, 0BF”, page
123

6.1.1 Overview of fitting locations - oil seals, 0BC, 0BD

1 - Protective ring (right-side)

❑ Renewing ⇒ page 154
2 - Oil seal (right-side)
❑ Renewing ⇒ page 130
3 - Oil seal (left-side)
❑ Renewing ⇒ page 123
4 - Protective ring (left-side)
❑ Renewing ⇒ page 154
5 - Input shaft oil seal
❑ Renewing ⇒ page 130
6 - Protective ring on input
shaft
❑ Renewing ⇒ page 161

122 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

6.1.2 Overview of fitting locations - oil seals, 0BE, 0BF

1 - Protective ring (right-side)

❑ Renewing ⇒ page 158
2 - Oil seal (right-side)
❑ Renewing ⇒ page 130
3 - Oil seal (left-side)
❑ Renewing ⇒ page 128
4 - Protective ring (left-side)
❑ Renewing ⇒ page 158
5 - Input shaft oil seal
❑ Renewing ⇒ page 130
6 - Protective ring on input
shaft
❑ Renewing ⇒ page 164

6.2 Renewing oil seal (left-side)

⇒ “6.2.1 Renewing oil seal (left-side), 0BC”, page 123
⇒ “6.2.2 Renewing oil seal (left-side), 0BD”, page 126
⇒ “6.2.3 Renewing oil seal (left-side), 0BE, 0BF”, page 128

6.2.1 Renewing oil seal (left-side), 0BC

• This chapter also contains “Renewing oil seal (right-side)”.
• The oil seals can only be renewed with the final drive removed.
Special tools and workshop equipment required

6. Oil seals 123

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♦ Puller - T10037-

♦ Drift - VW 295-

♦ Thrust piece - T40108-

♦ Sealing grease - G 052 128 A1-

Removing
– Observe the general repair instructions ⇒ page 14 .
– Remove rear final drive ⇒ page 48 .
Removing flange shaft (right-side)
– Secure puller - T10037- to housing -arrow- and pull out flange
shaft.

124 Rep. gr.39 - Final drive - rear differential

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Removing flange shaft (left-side)

– Secure puller - T10037- to housing -arrow- and pull out flange
shaft.

– Pry out oil seal with a suitable assembly lever.

Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:

Installing oil seal (right-side)

– Lightly lubricate outer circumference of oil seal with gear oil.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Drive in new oil seal onto stop (take care to keep oil seal
straight).

Installing oil seal (left-side)

– Lightly lubricate outer circumference of oil seal with gear oil.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Drive in new oil seal onto stop (take care to keep oil seal
straight).

6. Oil seals 125

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Installing flange shaft (right and left)

– Drive in flange shaft with drift - VW 295- .
– Install rear final drive ⇒ page 48 .
– Check oil level in rear final drive ⇒ page 107 .

6.2.2 Renewing oil seal (left-side), 0BD

• This chapter also contains “Renewing oil seal (right-side)”.
• The oil seals can only be renewed with the final drive removed.
Special tools and workshop equipment required
♦ Drift - VW 295-

♦ Puller - T10037-

♦ Thrust piece - T40110-

126 Rep. gr.39 - Final drive - rear differential

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♦ Thrust piece - T40111-

♦ Sealing grease - G 052 128 A1-

– Observe the general repair instructions ⇒ page 14 .
– Remove rear final drive ⇒ page 48 .

Removing flange shaft (left-side)

– Secure puller - T10037- to housing -arrow- and pull out flange
shaft.

Removing flange shaft (right-side)

– Secure puller - T10037- to housing -arrow- and pull out flange
shaft.

– Pry out oil seal with a suitable assembly lever.

6. Oil seals 127

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Installing oil seal (left-side)

– Lightly lubricate outer circumference of oil seal with gear oil.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Drive in new oil seal onto stop (take care to keep oil seal
straight).

Installing oil seal (right-side)

– Lightly lubricate outer circumference of oil seal with gear oil.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Drive in new oil seal onto stop (take care to keep oil seal
straight).

Before installing flange shaft, check protective ring for damage.

Renew protective ring if necessary ⇒ page 156 .
– Remove old circlip -A- from groove in flange shaft using pliers .
B - Protective jaw covers
– Insert new circlip in groove in flange shaft, taking care not to
overstretch circlip.

Installing flange shaft (right and left)

– Drive in flange shaft with drift - VW 295- .
– Install rear final drive ⇒ page 48 .
– Check oil level in rear final drive ⇒ page 108 .

6.2.3 Renewing oil seal (left-side), 0BE, 0BF

• This chapter also contains “Renewing oil seal (right-side)”.
• The oil seals can only be renewed with the final drive removed.
Special tools and workshop equipment required

128 Rep. gr.39 - Final drive - rear differential

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♦ Multi-purpose tool - VW 771-

♦ Thrust piece - T40221-

♦ ATF
Removing
– Observe the general repair instructions ⇒ page 14 .
– Remove rear final drive ⇒ page 48 .
– Remove flange shaft securing bolt. To do this, screw two bolts
into flange and counterhold flange shaft with tyre iron or other
suitable lever.
– Pull out flange shaft.

Note

If flange shaft cannot be pulled out by hand, use multi-purpose

tool -VW 771-.

– Pull out flange shaft oil seal using -VW 771- and -VW 771/37- .
Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:

Installing oil seal (right-side)

– Coat outer circumference and sealing lips of oil seal with ATF.
– Drive in new oil seal onto stop (take care to keep seal straight).

6. Oil seals 129

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Installing oil seal (left-side)

– Coat outer circumference and sealing lips of oil seal with ATF.
– Drive in new oil seal onto stop (take care to keep seal straight).
– Install flange shaft.

Note

If flange shaft cannot be inserted as far as stop by hand, knock it

in using a plastic hammer.

– Tighten new bolt securing flange shaft to specified torque

⇒ Item 1 (page 91) .
– Install rear final drive ⇒ page 48 .
– Check ATF level in rear final drive ⇒ page 116 .

6.3 Renewing oil seal (right-side)

Note

The procedure for renewing the oil seal (right-side) is described

in the chapter “Renewing oil seal (left-side)”.

⇒ “6.2.1 Renewing oil seal (left-side), 0BC”, page 123

⇒ “6.2.2 Renewing oil seal (left-side), 0BD”, page 126
⇒ “6.2.3 Renewing oil seal (left-side), 0BE, 0BF”, page 128

6.4 Renewing input shaft oil seal

⇒ “6.4.1 Renewing input shaft oil seal, 0BC”, page 130
⇒ “6.4.2 Renewing input shaft oil seal, 0BD”, page 137
⇒ “6.4.3 Renewing input shaft oil seal, 0BE”, page 142
⇒ “6.4.4 Renewing input shaft oil seal, 0BF”, page 147

6.4.1 Renewing input shaft oil seal, 0BC

Special tools and workshop equipment required
♦ Drive flange installing tool - VW 391-

130 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
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♦ Adapter - VW 771/40- from multi-purpose tool set - VW 771-

♦ Counterhold tool - 3028-

♦ Puller - T10055-

♦ -2- Adapter - T10055/2-

♦ Thrust piece - T40109-

6. Oil seals 131

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♦ Assembly sleeve - T40222/1-

♦ Sealing grease - G 052 128 A1-

♦ Bolts (2x) M 8 x 30
♦ Bolts (1x) M 8 x 45
Removing
• Rear final drive installed
• Refer to general repair instructions ⇒ page 14 .
– Disconnect exhaust system at clamps -1- and -2-.
– Remove rear section of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencers; Exploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Unscrew gear oil drain plug -arrow- and drain off approx. 250
ml of gear oil.
– Screw in and tighten drain plug -arrow-.
• Tightening torque: 30 Nm

– Detach propshaft from rear final drive ⇒ page 39 .

Audi A8
– Guide propshaft downwards between fuel tank and rear sub‐
frame and tie up on one side.

132 Rep. gr.39 - Final drive - rear differential

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Audi A4, A5 Coupé/Sportback/Cabriolet, Q5

– If fitted, remove front cross member -2-.
– Remove rear cross member -3- and heat shield -1-.

Audi A6 and A7
– Remove cross-piece -2- ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody trim .
Continued for all vehicles (except Audi A8)

– Remove bolts -arrows- securing centre propshaft bearing.

– Lower propshaft at centre bearing.
– When doing so, guide propshaft downwards between fuel tank
and rear subframe.
– Fit bolts -arrows- for centre bearing and hand-tighten.
– Tie propshaft to one side.

Continued for all vehicles

– Remove high-temperature grease in propshaft flange on rear
final drive.
– Remove circlip -arrow-.

Caution

Renew circlip with new circlip of same thickness if overstretch‐

ed or damaged during removal. For correct version, refer to ⇒
Electronic parts catalogue .

6. Oil seals 133

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– Mark position of flange -B- for propshaft relative to pinion shaft

-A- -arrow-.

Note

♦ This marking -arrow- is necessary in order to maintain the

original position of the coloured dot -C- on the outside of the
flange.
♦ This is the only effective way to minimise the imbalance in the
rear final drive.

– Screw 2 bolts M 8 x 30 -arrow- into flange.

– Pull off propshaft flange using drive flange installing tool - VW
391- .

– Lay absorbent cloth -A- on subframe under final drive.

– Pierce metal ring of oil seal -A- in direction of -arrow - using

e.g. a scriber -B-.

134 Rep. gr.39 - Final drive - rear differential

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– Then screw a self-tapping screw -arrow- into this hole in oil

seal -A-.

– Pull out oil seal -A- for propshaft flange in direction of

-arrow-.
-B- Self-tapping screw

Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Fit new oil seal -A- on assembly sleeve - T40222/1- .

Note

Check that spring of oil seal behind sealing lip is in installation

position.

– Lightly lubricate outer circumference of oil seal with gear oil.

– Fit assembly sleeve - T40222/1- onto pinion shaft -B- together
with oil seal -A-.
– Push oil seal -A- in as far as it will go.
– Remove assembly sleeve - T40222/1- .

– Drive in new oil seal onto stop (take care to keep oil seal
straight).

6. Oil seals 135

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– Position propshaft flange -B- on pinion shaft -A- so that mark‐

ings -arrow- are in line.

– Screw adapter - VW 771/40- into threaded hole in pinion shaft.

– Attach counterhold tool - 3028- to flange for propshaft with
bolts (M 8 x 30) -arrows A-.
– Secure installing tool - VW 391- with bolt (M 8 x 45)
-arrow B-. At the same time, screw spindle of installing tool into
adapter - VW 771/40- .
– Pull in flange for propshaft as far as stop (counterhold spindle
of installing tool with spanner).

Install circlip -1- as follows:

• Chamfer on inner diameter of circlip -arrow A- must face out‐
wards towards propshaft.
• If provided, the wider lug on the circlip -arrow B- must be on
the right side, as shown in the illustration.
When renewing flange for propshaft, please note:
• The thickness of the circlip -1- must be re-determined.
• To do so, determine the thickest circlip -1- that will just fit in
the groove and install it. For part number refer to ⇒ Electronic
parts catalogue .

136 Rep. gr.39 - Final drive - rear differential

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– Attach propshaft to rear final drive ⇒ page 40 .

Audi A4, A5 Coupé/Sportback/Cabriolet, Q5, A6, A7
– Secure centre propshaft bearing to body so it is free of stress.
Tightening torque ⇒ Item 9 (page 20)
– Install heat shield and cross member ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim; Exploded view - un‐
derbody trim .
Continued for all vehicles
– Check oil level in rear final drive ⇒ page 107 .
– Install rear section of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Exploded view - silencers .

6.4.2 Renewing input shaft oil seal, 0BD

• Original flange for propshaft must be re-installed.
• If flange for propshaft also has to be renewed, please use the
following description: ⇒ page 156 .

Special tools and workshop

equipment required
♦ Drive flange installing tool -
VW 391-
♦ Multi-purpose tool - VW
771-
♦ Extractor hook - VW
771/37-
♦ Thrust piece - T40112-
♦ Counterhold tool - 3028-
♦ Drift sleeve - 3143-

6. Oil seals 137

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♦ Adapter - T10235-

♦ Friction gauge - VAS 6222-

♦ Inductive heater - VAS 6414-

♦ Sealing grease - G 052 128 A1-
♦ Locking fluid - AMV 185 101 A1-
♦ 3 bolts M8 x 25
♦ 2 bolts (M10 x 40)
Removing
• The oil seal for the propshaft flange can only be renewed with
the rear final drive removed.
Refer to general repair instructions ⇒ page 14 .
– Remove rear final drive ⇒ page 48 .
– Secure rear final drive to engine and gearbox support - VW
540- with bolts (M10 × 40) -arrows-.

138 Rep. gr.39 - Final drive - rear differential

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– Measure friction torque before slackening pinion shaft nut.

– Make a note of the measurement.

Caution

This value must be reproduced on assembly if you find that the

flange for the propshaft has to be renewed as part of the repair
⇒ page 156 .

– Mark position of pinion shaft nut relative to pinion shaft

-arrow-.

Calculate dimension "a" and dimension "b"

♦ Distance from flange to pinion shaft = dimension -a-
♦ Distance from flange to pinion shaft nut = dimension -b-
– Note measurements.

– Fit counterhold tool - 3028- to flange for propshaft with bolts

-A-.
– Secure adapter - T10235- in tapped hole below flange for
propshaft.
– Slacken pinion shaft nut, allowing counterhold tool - 3028- to
rest against adapter - T10235- -arrow-.
– Count the turns when screwing off the pinion shaft nut and
make a note of the number.
-A- 3 bolts M 8 x 25
-B- Socket (32 mm)
-C- Handle

6. Oil seals 139

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– Mark position of flange for propshaft -arrow A- in relation to

pinion shaft -arrow B-.

– Place drip tray underneath.

– Secure installing tool - VW 391- with 2 bolts M 8 x 25
-arrows-.
– Pull off flange for propshaft.

– Pull out the oil seal.

– Clean thread of pinion shaft.

Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Lightly lubricate outer circumference of oil seal with gear oil.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Drive in new oil seal onto stop (take care to keep oil seal
straight).

140 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Using inductive heater - VAS 6414- , heat flange for propshaft

to approx. 80 °C.
– Align mark on flange for propshaft -arrow A- with mark on pin‐
ion shaft -arrow B-.

– Drive flange for propshaft onto pinion shaft.

– Install originally fitted pinion shaft nut with locking fluid - AMV
185 101 A1- .

– Fit counterhold tool - 3028- to flange for propshaft with bolts

-A-.
– Counterhold tool - 3028- must rest against lug -arrow- on
housing when tightening pinion shaft nut.
-A- 3 bolts M 8 x 25
-B- Socket (32 mm)
-C- Handle

– Tighten pinion shaft nut to the previously marked position

-arrow- by turning the same number of turns as noted on re‐
moval.

6. Oil seals 141

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Checking dimension “a” and dimension “b”

• The measurements must be the same as noted previously
within a tolerance of ± 0.2 mm.
– Install rear final drive ⇒ page 48 .
– Check oil level in rear final drive ⇒ page 108 .

6.4.3 Renewing input shaft oil seal, 0BE

Special tools and workshop equipment required
♦ Thrust piece - VW 431-

♦ Puller - T10055-

♦ -2- Adapter - T10055/2-

142 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Thrust piece - T10380-

♦ Assembly tool - T40247-

♦ Assembly sleeve - T40247/1-

♦ -1- Two-arm puller - Kukko 20/10-

♦ Inductive heater - VAS 6414-

♦ or
♦ Hotplate (commercially available)
♦ and
♦ Temperature gauge - VAS 6519-

6. Oil seals 143

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Drip tray
♦ Sealing grease - G 052 128 A1-
Removing
• Rear final drive installed
– Disconnect exhaust system at clamps -1- and -2-.
– Remove rear section of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencers; Exploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Unscrew gear oil drain plug -arrow- and drain off approx. 300
ml of gear oil.
– Screw in and tighten new drain plug -arrow-. Tightening torque
⇒ Item 17 (page 92)

– Detach propshaft from rear final drive ⇒ page 39 .

– Guide propshaft downwards between fuel tank and rear sub‐
frame and tie up on one side.

– Remove high-temperature grease in propshaft flange on rear

final drive.
– Remove circlip -arrow-.

144 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Mark position of flange -B- for propshaft relative to pinion shaft

-A- -arrow-.

Note

♦ This marking -arrow- is necessary in order to maintain the

original position of the coloured dot -C- on the outside of the
flange.
♦ This is the only effective way to minimise the imbalance in the
rear final drive.

– Pull off propshaft flange.

A - E.g. two-arm puller - Kukko 20-10-

– Lay absorbent cloth -A- on subframe under final drive.

– Pierce metal ring of oil seal -A- in direction of -arrow - using

e.g. a scriber -B-.

6. Oil seals 145

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– Then screw a self-tapping screw -arrow- into this hole in oil

seal -A-.

– Pull out oil seal -A- for propshaft flange in direction of

-arrow-.
B - Self-tapping screw

Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Lightly lubricate outer circumference of oil seal with gear oil.
– Fit new oil seal -A- on assembly sleeve - T40247/1- .

Note

Check that spring of oil seal behind sealing lip is in installation

position.

– Fit assembly sleeve - T40247/1- onto pinion shaft -B- together

with oil seal -A-.

– Drive in new oil seal onto stop (take care to keep seal straight).

146 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Heat propshaft flange -B- to 115 °C using inductive heater -

VAS 6414- or a hotplate .

WARNING

♦ Wear protective gloves.

♦ If using a hotplate , the temperature value must be moni‐
tored constantly with temperature gauge - VAS 6519- .

– Position propshaft flange -B- on pinion shaft -A- so that mark‐

ings -arrow- are in line.

– Drive on propshaft flange as far as stop using thrust piece -

T10380- .

Install circlip -1- as follows:

• Always renew circlip -1-.
• Chamfer on inner diameter of circlip -arrow A- must face out‐
wards towards propshaft.
• The wider lug on the circlip -arrow B- must be on the right side,
as shown in the illustration.
– Measure thickness of old circlip -1-.
– Replace circlip -1- with a new circlip of the same thickness ⇒
Electronic parts catalogue .
– Fit new circlip -1-.

Note

♦ If the propshaft flange is being renewed, the thickness of the

circlip -arrow- must be re-determined.
♦ To do so, determine the thickest circlip -arrow- that will just fit
in the groove and install it. For part number refer to ⇒ Elec‐
tronic parts catalogue .

– Fill up gear oil in rear final drive 0BE ⇒ page 111 .

– Attach propshaft to rear final drive ⇒ page 40 .
– Install rear section of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Exploded view - silencers .

6.4.4 Renewing input shaft oil seal, 0BF

Special tools and workshop equipment required

6. Oil seals 147

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Drive flange installing tool - VW 391-

♦ Puller - T10055-

♦ -2- Adapter - T10055/2-

♦ Bolts (2x) M 8 x 30
♦ Thrust piece - T10380-

♦ Thrust piece - T40222-

♦ Assembly sleeve - T40222/1-

♦ Sealing grease - G 052 128 A1-

148 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Inductive heater - VAS 6414-

♦ or
♦ Hotplate (commercially available)
♦ and
♦ Temperature gauge - VAS 6519-
Removing
• Rear final drive installed
• Refer to general repair instructions ⇒ page 14 .
– Disconnect exhaust system at clamps -1- and -2-.
– Remove rear section of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencers; Exploded view - silencers .

Note

A second mechanic is required for removing the rear section of

the exhaust system.

– Unscrew gear oil drain plug -2- and drain off approx. 300 ml of
gear oil.
– Screw in and tighten new drain plug -2-. Tightening torque
⇒ Item 17 (page 92)

– Detach propshaft from rear final drive ⇒ page 39 .

Audi A8
– Guide propshaft downwards between fuel tank and rear sub‐
frame and tie up on one side.

6. Oil seals 149

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Audi A4, A5 Coupé/Sportback/Cabriolet

– If fitted, remove front cross member -2-.
– Remove rear cross member -3- and heat shield -1-.

Audi A6 and A7
– Remove cross-piece -2- ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody trim .

Audi A4, A5 Coupé/Sportback/Cabriolet, A6, A7

– Remove bolts -arrows- securing centre propshaft bearing.
– Lower propshaft at centre bearing.
– When doing so, guide propshaft downwards between fuel tank
and rear subframe.
– Fit bolts -arrows- for centre bearing and hand-tighten.
– Tie propshaft to one side.

Continued for all vehicles

– Remove high-temperature grease in propshaft flange on rear
final drive.
– Remove circlip -arrow-.

150 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Mark position of flange -B- for propshaft relative to pinion shaft

-A- -arrow-.

Note

♦ This marking -arrow- is necessary in order to maintain the

original position of the coloured dot -C- on the outside of the
flange.
♦ This is the only effective way to minimise the imbalance in the
rear final drive.

– Screw 2 bolts M 8 x 30 mm -arrow- into flange.

– Pull off propshaft flange using drive flange installing tool - VW
391- .

– Lay absorbent cloth -A- on subframe under final drive.

– Pierce metal ring of oil seal -A- in direction of -arrow - using

e.g. a scriber -B-.

6. Oil seals 151

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Then screw a self-tapping screw -arrow- into this hole in oil

seal -A-.

– Pull out oil seal -A- for propshaft flange in direction of

-arrow-.
-B- Self-tapping screw

Installing
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Fit new oil seal -A- on assembly sleeve - T40222/1- .

Note

Check that spring of oil seal behind sealing lip is in installation

position.

– Lightly lubricate outer circumference of oil seal with gear oil.

– Fit assembly sleeve - T40222/1- onto pinion shaft -B- together
with oil seal -A-.

– Drive in new oil seal onto stop (take care to keep seal straight).

152 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Heat propshaft flange -B- to 115 °C using inductive heater -

VAS 6414- or a hotplate .

WARNING

♦ Wear protective gloves.

♦ If using a hotplate , the temperature value must be moni‐
tored constantly with temperature gauge - VAS 6519- .

– Position propshaft flange -B- on pinion shaft -A- so that mark‐

ings -arrow- are in line.

– Drive on propshaft flange as far as stop using thrust piece -

T10380- .

6. Oil seals 153

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Install circlip -1- as follows:

• Always renew circlip -1-.
• Chamfer on inner diameter of circlip -arrow A- must face out‐
wards towards propshaft.
• The wider lug on the circlip -arrow B- must be on the right side,
as shown in the illustration.
– Measure thickness of old circlip -1-.
– Replace circlip -1- with a new circlip of the same thickness ⇒
Electronic parts catalogue .
– Fit new circlip -1-.

Note

♦ If the propshaft flange is being renewed, the thickness of the

circlip -arrow- must be re-determined.
♦ To do so, determine the thickest circlip -arrow- that will just fit
in the groove and install it. For part number refer to ⇒ Elec‐
tronic parts catalogue .

– Top up gear oil in rear final drive 0BF ⇒ page 113 .

– Attach propshaft to rear final drive ⇒ page 40 .
Audi A4, A5 Coupé/Sportback/Cabriolet, A6, A7
– Secure centre propshaft bearing to body so it is free of stress.
Tightening torque ⇒ Item 9 (page 20)
– Install heat shield and cross member ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim; Exploded view - un‐
derbody trim .
Continued for all vehicles
– Install rear section of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Exploded view - silencers .

6.5 Renewing protective ring on flange shaft

⇒ “6.5.1 Renewing protective ring on flange shaft, 0BC”,
page 154
⇒ “6.5.2 Renewing protective ring on flange shaft, 0BD”,
page 156
⇒ “6.5.3 Renewing protective ring on flange shaft, 0BE, 0BF”,
page 158

6.5.1 Renewing protective ring on flange

shaft, 0BC
• The protective rings can only be renewed with the final drive
and flange shafts removed.
Special tools and workshop equipment required

154 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-

♦ Press tool - VW 412-

♦ Tube - 3146-

6. Oil seals 155

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ -3- Splitter 22...115 mm , e.g. -Kukko 17/2-

• Rear final drive removed ⇒ page 48

• Flange shaft removed ⇒ page 123
Pressing protective ring -A- off flange shaft
B - Splitter 22...115 mm , e.g. -Kukko 17/2-

Pressing protective ring -A- onto flange shaft

• Installation position of protective ring -A-: larger outside diam‐
eter of protective ring faces towards flange

6.5.2 Renewing protective ring on flange

shaft, 0BD
• The protective rings can only be renewed with the final drive
and flange shafts removed.
Special tools and workshop equipment required
♦ Thrust plate - VW 401-

156 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Thrust plate - VW 402-

♦ Press tool - VW 407-

♦ Tube - 32 - 119-

♦ Thrust pad - 3062-

6. Oil seals 157

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ -3- Splitter 22...115 mm , e.g. -Kukko 17/2-

• Rear final drive removed ⇒ page 48

• Flange shaft removed ⇒ page 126
Pressing protective ring -B- off flange shaft
A - Splitter 22...115 mm , e.g. -Kukko 17/2-

Pressing protective ring -A- onto flange shaft

• Installation position of protective ring -A-: recess in protective
ring faces towards tube - 32 - 119- .

6.5.3 Renewing protective ring on flange

shaft, 0BE, 0BF
• The protective rings can only be renewed with the final drive
and flange shafts removed.
Special tools and workshop equipment required
♦ Thrust plate - VW 401-

158 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Thrust plate - VW 402-

♦ Press tool - VW 412-

♦ Press tool - 40 - 21-

♦ Installing ring - 2003/1- from fitting tool - 2003-

6. Oil seals 159

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Wheel bearing tube - 3345-

♦ -3- Splitter 22...115 mm , e.g. -Kukko 17/2-

• Rear final drive removed ⇒ page 48

• Flange shaft removed ⇒ page 128
Pressing protective ring -A- off flange shaft
B - Splitter 22...115 mm , e.g. -Kukko 17/2-

Pressing protective ring -A- onto flange shaft (press on carefully)

• Installation position of protective ring -A-: larger outside diam‐
eter of protective ring faces towards wheel bearing tube -
3345-

160 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

6.6 Renewing protective ring on input shaft

flange
⇒ “6.6.1 Renewing protective ring on input shaft flange, 0BC”,
page 161
⇒ “6.6.2 Renewing protective ring on input shaft flange, 0BD”,
page 163
⇒ “6.6.3 Renewing protective ring on input shaft flange, 0BE,
0BF”, page 164

6.6.1 Renewing protective ring on input shaft

flange, 0BC
• The protective ring can only be renewed with the input shaft
removed.
Special tools and workshop equipment required
♦ Adapter - VW 295 A-

♦ Thrust plate - VW 402-

♦ Press tool - VW 408 A-

6. Oil seals 161

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Support rails - VW 457-

♦ -3- Splitter 22...75 mm , e.g. -Kukko 17/1-

• Input shaft removed ⇒ page 130

Pressing protective ring -A- off flange for propshaft
B - Splitter 12...75 mm , e.g. -Kukko 17/1-

Installation position of protective ring -A- on flange for propshaft

• The projecting ridge -arrow 1- on the protective ring -A- must
be fitted in the annular groove -arrow 2- on the flange -B-. The
smaller outside diameter -arrow 3- then faces towards the
flange.

162 Rep. gr.39 - Final drive - rear differential

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Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

Pressing protective ring -A- onto flange for propshaft

• The protective ring -A- must engage in the annular groove on
the flange ⇒ page 162 .

6.6.2 Renewing protective ring on input shaft

flange, 0BD
• The protective ring can only be renewed with the input shaft
removed.
Special tools and workshop equipment required
♦ Thrust plate - VW 402-

♦ Press tool - VW 407-

♦ Press tool - VW 412-

6. Oil seals 163

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Drift sleeve - 40 - 20-

♦ -3- Splitter 22...75 mm , e.g. -Kukko 17/1-

• Input shaft removed ⇒ page 137

Pressing protective ring off flange for propshaft
A - Splitter 22...115 mm , e.g. -Kukko 17/2-

Pressing protective ring -A- onto flange for propshaft

• Installation position of protective ring -A-: recess in protective
ring faces upwards towards drift sleeve - 40 - 20- .

6.6.3 Renewing protective ring on input shaft

flange, 0BE, 0BF
• The protective ring can only be renewed with the input shaft
removed.
Special tools and workshop equipment required

164 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Adapter - VW 295 A-

♦ Thrust plate - VW 402-

♦ Press tool - VW 408 A-

♦ Support rails - VW 457-

6. Oil seals 165

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ -3- Splitter 22...75 mm , e.g. -Kukko 17/1-

• Input shaft removed: 0BE ⇒ page 142 , 0BF ⇒ page 147

Pressing protective ring -A- off flange for propshaft
B - Splitter 12...75 mm , e.g. -Kukko 17/1-

Installation position of protective ring -A- on flange for propshaft

• The projecting ridge -arrow 1- on the protective ring -A- must
be fitted in the annular groove -arrow 2- on the flange -B-. The
smaller outside diameter -arrow 3- then faces towards the
flange.

Pressing protective ring -A- onto flange for propshaft

• The protective ring -A- must engage in the annular groove on
the flange ⇒ page 166 .

166 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

7 Renewing propshaft flange, 0BD

• (Rear final drive removed)

Special tools and workshop

equipment required
♦ Drive flange installing tool -
VW 391-
♦ Multi-purpose tool - VW
771-
♦ Extractor tool - VW 771/37-
♦ Thrust piece - T40112-
♦ Counterhold tool - 3028-
♦ Drift sleeve - 3143-

♦ Adapters - T10235-

7. Renewing propshaft flange, 0BD 167

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

♦ Friction gauge - VAS 6222-

♦ Inductive heater - VAS 6414-

♦ Sealing grease - G 052 128 A1-
♦ Locking fluid - AMV 185 101 A1-
♦ 3 bolts M8 x 25
♦ 2 bolts (M10 x 40)
Refer to general repair instructions ⇒ page 14 .
– Remove rear final drive ⇒ page 48 .
– Secure rear final drive to engine and gearbox support - VW
540- with bolts (M10 × 40) -arrows-.

– Measure friction torque before slackening pinion shaft nut.

– Make a note of the measurement.

Caution

The friction torque must be set to this measured value after

renewing the oil seal.

168 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Fit counterhold tool - 3028- to flange for propshaft with bolts

-A-.
– Secure adapter - T10235- in tapped hole below flange for
propshaft.
– Slacken pinion shaft nut, allowing counterhold tool - 3028- to
rest against adapter - T10235- -arrow-.
-A- 3 bolts M 8 x 25
-B- Socket (32 mm)
-C- Handle

– Secure installing tool - VW 391- with 2 bolts M 8 x 25

-arrows-.
– Pull off flange for propshaft.

– Pull out the oil seal.

– Clean thread of pinion shaft.

– Lightly lubricate outer circumference of oil seal with gear oil.

– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Drive in new oil seal onto stop (take care to keep oil seal
straight).

7. Renewing propshaft flange, 0BD 169

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Using inductive heater - VAS 6414- , heat flange for propshaft

to approx. 80 °C.
– Drive new flange for propshaft onto pinion shaft.
– Apply locking fluid - AMV 185 101 A1- to thread of new nut.

– Fit counterhold tool - 3028- to flange for propshaft with bolts

-A-.
– Counterhold tool - 3028- must rest against lug -arrow- on
housing when tightening pinion shaft nut.
-A- 3 bolts M 8 x 25
-B- Socket (32 mm)
-C- Handle

Caution

Only increase tightening torque slowly. Stop and check friction

torque several times. Friction torque measured prior to removal
must not be exceeded otherwise rear final drive will have to be
renewed!

– Tighten new pinion shaft nut until torque friction measured be‐
fore removal is attained.
– Install rear final drive ⇒ page 48 .
– Check oil level in rear final drive ⇒ page 108 .

170 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

8 Gearbox control system

⇒ “8.1 Overview of fitting locations - gearbox control system”,
page 171
⇒ “8.2 Removing and installing all-wheel drive control unit J492 ”,
page 172
⇒ “8.3 Additional work required after renewing all-wheel drive
control unit J492 ”, page 173

8.1 Overview of fitting locations - gearbox

control system
Diagnostic connection
Fitting location: the diagnostic connection for the vehicle diag‐
nostic tester is located in the driver's footwell.

All-wheel drive control unit - J492- in A4 saloon, A5 Coupé and

A5 Cabriolet
Fitting location: the all-wheel drive control unit - J492- -A- is lo‐
cated in the spare wheel well in front of the battery.
⇒ “8.2 Removing and installing all-wheel drive control unit J492 ”,
page 172

All-wheel drive control unit - J492- in A4 Avant

Fitting location: the all-wheel drive control unit - J492- -1- is loca‐
ted on the right of the luggage compartment in front of the spare
wheel well.
⇒ “8.2 Removing and installing all-wheel drive control unit J492 ”,
page 172

8. Gearbox control system 171

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

All-wheel drive control unit - J492- in A5 Sportback

Fitting location: the all-wheel drive control unit - J492- -1- is loca‐
ted on the rear wheel housing (right-side) behind the luggage
compartment side trim ⇒ General body repairs, interior; Rep. gr.
70 ; Luggage compartment trim panels .
⇒ “8.2 Removing and installing all-wheel drive control unit J492 ”,
page 172

All-wheel drive control unit - J492- in Audi A6/A7

Fitting location: the all-wheel drive control unit - J492- -A- is lo‐
cated on the right side of the spare wheel well.
⇒ “8.2 Removing and installing all-wheel drive control unit J492 ”,
page 172

All-wheel drive control unit - J492- in A8

Fitting location: the all-wheel drive control unit - J492- -1- is loca‐
ted on the left side of the spare wheel well.
⇒ “8.2 Removing and installing all-wheel drive control unit J492 ”,
page 172

8.2 Removing and installing all-wheel drive

control unit - J492-

Note

♦ Fitting locations of all-wheel drive control unit - J492-

⇒ page 171
♦ The removal and installation procedures are described for the
A4 saloon.

• Ignition is switched off.

– Remove luggage compartment floor covering.
– Remove cover and mounting for vehicle tool kit.

172 Rep. gr.39 - Final drive - rear differential

 Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear final drive 0BC, 0BD, 0BE, 0BF - Edition 06.2015

– Remove all-wheel drive control unit - J492- -A- from bracket

-C-.
– Release connector -B- and unplug from all-wheel drive control
unit - J492- .
– Installation of all-wheel drive control unit - J492- is carried out
in reverse order of removal.
• Additional work is required if all-wheel drive control unit - J492-
has been renewed ⇒ page 173 .

8.3 Additional work required after renewing

all-wheel drive control unit - J492-

Note

Only perform this additional work if all-wheel drive control unit -

J492- has been renewed.

– Connect vehicle diagnostic tester and switch on ignition.

– Using vehicle diagnostic tester in Guided Functions mode,
select 22 - Four-wheel electronics and then select the
function 22 - Replace control unit .
• It is important to follow all instructions given by the vehicle di‐
agnostic tester exactly.
Using the vehicle diagnostic tester, the rear final drive fitted in the
vehicle is “adapted” to the all-wheel drive control unit - J492- .

Note

When the function 22 - Replace control unit has been com‐

pleted, a system check is performed. Any malfunctions during this
test must be eliminated via the “Guided Fault Finding”.

8. Gearbox control system 173