Service

Workshop Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
Audi A6 2005 ➤
Rear final drive 08V
Edition 12.2007

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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

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

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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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Audi AG, Ingolstadt A005AA00220

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Rear final drive identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Code letters, allocation, transmission ratios, capacities: Audi A4 2001 ▸, Cabriolet 2003 ▸
........................................................................ 2
1.2 Code letters, allocation, transmission ratios, capacities: Audi A6 2005 ▸ . . . . . . . . . . . . . . 2
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Jacking mode (vehicles with pneumatic suspension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Servicing propshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Detaching and attaching propshaft at rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Measuring and marking radial run-out at flange for propshaft . . . . . . . . . . . . . . . . . . . . . . 19
3 Checking gear oil in rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Exploded view – rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Renewing flange shaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Renewing flange shaft oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Renewing flange shaft oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3 Renewing protective ring on flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6 Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) . . . . . . 31
6.1 Renewing flange for propshaft and oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Contents i
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

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ii Contents
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

00 – Technical data
1 Rear final drive identification
The rear final drive 08V is installed in conjunction with the follow‐
ing gearbox types:
♦ 6-speed manual gearbox 02X
♦ 6-speed manual gearbox 0A3
♦ Automatic gearbox 09L, four-wheel drive
♦ Automatic gearbox 01V, four-wheel drive
• Allocation Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.1 Code letters, allocation, transmission ratios,
permitted unlesscapacities:
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Audi A4 2001 ▸, Cabriolet 2003 ▸”, page 2with respect to the correctness of information in this document. Copyright by AUDI AG.
• Allocation
⇒ “1.2 Code letters, allocation, transmission ratios, capacities:
Audi A6 2005 ▸”, page 2
Location on rear final drive
Final drive 08V, code letters and date of manufacture -arrow-

-Arrow A- Final drive 08V with Part No. (in this

example 08V 500 043)
-Arrow B- Code letters “HUN”
-Arrow C- Manufacturing data of rear final drive
Exam‐ E 096 3002
ple:
I I I
Year of manu‐ Day of manufac‐ Serial number on
facture -2005- ture day of manufacture
E = 2005, -96th day of year-
F = 2006, (always specified
G = 2007, in three digits)
H = 2008 ...
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.

1. Rear final drive identification 1

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

1.1 Code letters, allocation, transmission ratios, capacities: Audi A4 2001 ▸,

Cabriolet 2003 ▸
Rear final drive 08V
Code letters HUN HUP HUQ
Manufactured from 11.05 11.05 11.05
to
Allocation Engine 3.2 ltr. - 188 kW FSI 2.0 ltr. - 147 kW 2.0 ltr. - 120 kW TDI
TFSI 2.0 ltr. - 125 kW TDI
3.2 ltr. - 188 kW FSI 2.0 ltr. - 147 kW
TFSI
3.0 ltr. - 160 kW
Ratio Final drive 35 : 8 = 4.375 31 : 10 = 3.100 35 : 9 = 3.889
Z2 : Z1
Drive shaft flange ∅ 75.5 mm 75.5 mm 75.5 mm
Capacity 1.0 litre
Specifica‐ Gear oil G 052 145 A1 (container size 0.5 litre)
tion Gear oil G 052 145 S2 (container size 1.0 litre)
Select correct unit by checking engine, manual gearbox and automatic gearbox versions in ⇒ Electronic
parts catalogue .

1.2 Code letters, allocation, transmission ra‐

tios, capacities: Audi A6 2005 ▸
Rear final 08V
drive
Code let‐ HUN
ters
Manufac‐ from 11.05
tured to
Allo‐ En‐ 2.4 ltr. - 130
cation gin kW
e 3.2 ltr. -188
kW FSI
Ratio Final drive 35 : 8 =
Z2 : Z1 4.375
Drive shaft 75.5 mm
flange ∅
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Ca‐ 1.0 litrepermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
pacity with respect to the correctness of information in this document. Copyright by AUDI AG.

Speci‐ Gear oil G 052 145 A1 (container size

fica‐ 0.5 litre)
tion Gear oil G 052 145 S2 (container size
1.0 litre)
Select correct unit by checking engine, manual gearbox and
automatic gearbox versions in ⇒ Electronic parts catalogue .

2 Rep. Gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

2 Transmission layout
♦ Illustrated with 6-speed manual gearbox 0A3, four-wheel drive
Identification

Note

Arrows point in direction of travel

1 - Engine
2 - Clutch
3 - Manual gearbox
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- Input shaftby(main
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5 - Differential (front)
6 - Front pinion shaft (output
shaft)
7 - Hollow shaft
8 - Torsen differential
9 - Propshaft
10 - Rear pinion shaft
11 - Differential (rear)

Ratio

Note

Arrows point in direction of travel

2. Transmission layout 3
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A1 - Final drive (front)
A2 - Final drive (rear)

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4 Rep. Gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

3 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the final drive. The usual basic
safety precautions also naturally apply when carrying out repair
work.
A number of generally applicable instructions for the various re‐
pair procedures are summarised here under the designation
“Components” ⇒ page 5 . They apply to the work described in
this Manual.

3.1 Jacking mode (vehicles with pneumatic

suspension)
Before raising the vehicle on a 2-column lifting platform (wheels
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off the ground)
with respect you
to the must firstof activate
correctness information inthe jacking Copyright
this document. mode ⇒ Rep.
by AUDI AG.
Gr. 43 .

3.2 Special tools

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

3.3 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 and top up if necessary ⇒ page 20 .
♦ Capacity and specification, Audi A4 and Cabriolet
⇒ “1.1 Code letters, allocation, transmission ratios, capacities:
Audi A4 2001 ▸, Cabriolet 2003 ▸”, page 2
♦ Capacity and specification, Audi A6
⇒ “1.2 Code letters, allocation, transmission ratios, capacities:
Audi A6 2005 ▸”, page 2
♦ 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 surrounding areas before dis‐
mantling.

3. General repair instructions 5

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

O-rings, oil seals and gaskets

♦ Always renew O-rings, 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.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrow-
about half full with grease -G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Lightly lubricate O-rings before installation to prevent them
from being trapped and damaged during assembly.
♦ After renewing seals and gaskets, check and, if necessary, top
up oil level in final drive ⇒ page 20 .
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-.
Nuts, bolts
♦ 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.

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6 Rep. Gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

39 – Final drive - rear differential

1 Servicing propshaft - exploded view

Note

♦ Refer to general repair instructions ⇒ page 5 .

♦ 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, the ad‐
ditional balancing washer (thicker washer) that may be fitted
between the lock plate and the bolt head (hexagon socket bolt)
must not be reinstalled.
♦ If problems occur (noise or vibration), ensure that the centre
bearing is free of stress and check the radial runout of the
propshaft flange at the rear final drive before renewing the
propshaft ⇒ page 19 .

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1. Servicing propshaft - exploded view 7

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

1 - Rear final drive

❑ Removing and installing
⇒ page 21
2 - Gasket
❑ Renew
❑ Pull off protective foil
❑ Degrease flange shaft
and glue on gasket
3 - Propshaft
❑ Removing and installing
⇒ page 8
4 - Balancing washer
❑ Not fitted on all vehicles
❑ May be fitted between
one socket head bolt
⇒ Item 5 (page 8)
and one lock plate
⇒ Item 6 (page 8) at
rear final drive
❑ If fitted, this balancing
washer must not be re-
installed after the prop‐
shaft has been detach‐
ed from the rear final
drive.
5 - Hexagon socket-head bolt,
55 Nm
❑ Self-locking
❑ Always renew
❑ The tapped holes for the
bolts in the flange shafts
must always be cleaned
(e.g. with a thread tap)
❑ Use counterhold tool -
T10172- with adapters -T10172/5- to slacken and tighten
6 - Lock plate
7 - Centre bearing
8 - Hexagon bolt, 25 Nm
9 - Gearbox

1.1 Removing and installing propshaft

Special tools and workshop equipment required

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8 Rep. Gr.39 - Final drive - rear differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

♦ Assembly tool -3139-

♦ Removal lever -80 - 200-

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

♦ Engine/gearbox jack -V.A.G 1383 A- with universal gearbox

mounting -V.A.G 1359/2-

♦ High-temperature grease -G 000 633-

Removing propshaft
♦ Please refer to notes ⇒ page 7 .
♦ Repairs on the propshaft should be carried out on a two pillar
hoist.

1. Servicing propshaft - exploded view 9

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Disconnect exhaust system at clamps -arrows-.

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– Remove rear cross piece -1-, where fitted.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove rear section of exhaust system -2- ⇒ Rep. Gr. 26 .
Audi A6:
– Detach heat shield -3- from vehicle underbody -arrows-.

Audi A4 and Audi Cabriolet:

– Lever off fasteners -A- for heat shield above centre bearing.
– Unscrew securing bolts for centre bearing -B-. Support the
propshaft by hand during this procedure.
– Remove heat shield with propshaft supported.
– Fit securing bolts for centre bearing -B- again and hand-tight‐
en.

Continued for all vehicles:

– Where fitted, remove bolts securing front exhaust pipes -1-
and -2-.

10 Rep. Gr.39 - Final drive - rear differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Detach guard plate -A- from gearbox -arrows-.

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

-arrows A and B- on the propshaft flange and on the rear final
drive flange.
– If not, mark position of propshaft flange -arrow A- in relation to
rear final drive flange -arrow B- with paint marker.

– Attach assembly tool 3139 and tighten plastic nuts.

Note

Do not fit assembly tool onto

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– Remove bolts -arrows- securing centre bearing.

1. Servicing propshaft - exploded view 11

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Remove bolts from connection between propshaft and gear‐

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

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

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

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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 -G 000 633- .
♦ 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.
♦ Make sure that the marks on the propshaft flange -arrow A-
and on the gearbox/final drive flange -arrow B- are in line.
♦ If a new propshaft is being installed and the factory marking
on the rear final drive flange is no longer visible, the radial run-
out at the flange for the propshaft must be measured
⇒ page 19 , and the coloured marking on the new propshaft
must be aligned with the new marking on the flange.
– Gaskets for propshaft on flanges of gearbox and rear final
drive must be renewed. Degrease sealing surfaces and glue
on new gaskets.

12 Rep. Gr.39 - Final drive - rear differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Bring propshaft into position and fit new bolts at rear final drive
-arrows- and at gearbox.

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

be moved.

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– Tighten bolts -1- securing propshaft on rear final drive to speci‐

fied torque ⇒ Item 5 (page 8) .
– Use counterhold tool -T10172- with adapters -T10172/5- .

– Tighten bolts securing propshaft (front end) to specified setting

⇒ Item 5 (page 8) .
– Use counterhold tool -T10172- with adapters -T10172/5- .
– Remove assembly tool -3139- .

1. Servicing propshaft - exploded view 13

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

Audi A4 and Audi Cabriolet:

– Remove securing bolts -arrows-. The propshaft must be sup‐
ported by a second mechanic during this procedure.

– Install heat shield -2- (continue to support propshaft).

– Fit securing bolts -4- on left and right again and screw in a few
turns.
– Secure heat shield -2- on centre bearing -3- with one bolt on
each side -1- (M8 x 30).

Note

The centralising lug -arrow A- must fit in the locating hole

-arrow B- when tightening the bolt with washer -4-.

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

and tighten -2-. Tightening torque ⇒ Item 8 (page 8)
– Remove locating bolts -1-.
– Insert retaining clips for heat shield.

Audi A6:
– Secure centre propshaft bearing to body so it is free of stress
and tighten to specified torque ⇒ Item 8 (page 8) . The cen‐
tralising lugs on the centre bearing mounting must fit in the
locating holes -arrows-.

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14 Rep. Gr.39 - Final drive - rear differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Secure heat shield -3- to vehicle underbody -arrows-.

Continued for all vehicles:
– Install rear section of exhaust system -2- ⇒ Rep. Gr. 26 .
– Where fitted, install rear cross piece -1- ⇒ Rep. Gr. 40 .

– Secure guard plate -A- on gearbox -arrows-.

– Where required, secure front exhaust pipes -1- and -2- ⇒ Rep.
Gr. 26 .

– Tighten clamps -arrows- ⇒byRep.

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Tightening torques with respect to the correctness of information in this document. Copyright by AUDI AG.

Component Nm
Heat shield for propshaft to gearbox 25

1.2 Detaching and attaching propshaft at

rear final drive
Special tools and workshop equipment required

1. Servicing propshaft - exploded view 15

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

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

♦ High-temperature grease -G 000 633-

♦ Please refer to notes ⇒ page 7 .
♦ Repairs on the propshaft should be carried out on a two pillar
hoist.
Detaching propshaft from rear final drive
– Release clamps -1- and -2- and remove rear section of ex‐
haust system ⇒ Rep. Gr. 26 .

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

-arrows A and B- on the propshaft flange and on the rear final
drive flange.
– If not, mark position of propshaft flange -arrow A- in relation to
rear final drive flange -arrow B- with paint marker.

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

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Use counterhold tool -T10172- permitted
with adapters -T10172/5-
unless authorised . AUDI AG does not guarantee or accept any liability
by AUDI AG.
with respect to the correctness of information in this document. Copyright by AUDI AG.

16 Rep. Gr.39 - Final drive - rear differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Separate propshaft from rear final drive and tie up to one side
-arrow-.
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 G 000 633.
♦ 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).
– Gasket for propshaft on rear final drive flange must be re‐
newed. Degrease sealing surface and glue on new gasket.

– Make sure that the marks on the propshaft flange -arrow A-

and on the rear final drive flange -arrow B- are in line.

– Bring propshaft into position at rear final drive and fit new bolts
-arrows-.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Servicing propshaft - exploded view 17

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Tighten bolts -1- securing propshaft on rear final drive to speci‐

fied torque ⇒ Item 5 (page 8) .
– Use counterhold tool -T10172- with adapters -T10172/5- .
– Install rear section of exhaust system ⇒ Rep. Gr. 26 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

18 Rep. Gr.39 - Final drive - rear differential

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

2 Measuring and marking radial run-

out at flange for propshaft
Special tools and workshop equipment required
♦ Universal dial gauge bracket -VW 387-

♦ Dial gauge
♦ Bolt M10×30

Note

♦ The radial run-out must always be measured when the flange

for the propshaft at the rear final drive has been removed. Re‐
move old paint marking and make new marking.
♦ If a new propshaft is being installed and the marking on the
flange shaft of the rear final drive is no longer visible, the point
of maximum radial run-out (corresponding to the maximum
distance from the axis of rotation) must be measured with a
dial gauge and marked with a coloured dot -arrow B-.
♦ The coloured dot on the propshaft -arrow A- is then brought
into alignment with this marking -arrow B-.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ The radial run-out can be measured without
with respectremoving the ofrear
to the correctness information in this document. Copyright by AUDI AG.
final drive.

– Unbolt propshaft from rear final drive ⇒ page 15 .

– Secure measuring equipment to rear final drive with bolt -A-

(M10 x 30).
– Apply dial gauge to machined surface on inner side of flange
for propshaft -arrow- and set to “0” with a preload of 1 mm.
– Turn both rear wheels in the same direction to turn the flange
through one complete rotation.
– Mark point of maximum radial run-out with coloured dot on
outside of flange (corresponding to maximum distance from
axis of rotation).
– Then remove previous marking on flange.
– Attach propshaft ⇒ page 17 .

2. Measuring and marking radial run-out at flange for propshaft 19

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

3 Checking gear oil in rear final drive

Special tools and workshop equipment required
♦ Drip tray -V.A.G 1306-

♦ Torque wrench -V.A.G 1331-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove screw plug -arrow- to check gear permitted
oil. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
The oil level is correct when the rear final drive is filled to the
bottom lip of the filler hole.
• Gear oil specifications: Audi A4 2001 >, Cabriolet 2003 >
⇒ page 2
• Gear oil specifications: Audi A6 2005 > ⇒ page 2
– Screw in plug -arrow- and tighten.
Tightening torque: 45 Nm

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

4 Exploded view – rear final drive

1 - Subframe
♦ Removing and installing ⇒
Rep. Gr. 42
2 - Hexagon bolt
3 - Hexagon bolt, 40 Nm
♦ Secures final drive support
to subframe
♦ Renew nut if fitted
4 - Hexagon socket head bolts,
40 Nm
5 - Rear cross member
6 - Washer
7 - Nut
♦ Self-locking
♦ Renew
♦ Tightening torque ⇒ Rep.
Gr. 42
8 - Rear final drive
♦ Removing and installing
⇒ page 21
♦ Mounting on assembly
stand ⇒ page 21
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted9 unless
- Drive shaftby AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Removing and installing ⇒
Rep. Gr. 42
10 - Guard plate
11 - Hexagon socket head
bolts, 25 Nm
12 - Final drive support
13 - Hexagon socket head bolts, 40 Nm

Securing rear final drive to assembly stand

4.1 Removing and installing rear final drive

Special tools and workshop equipment required

4. Exploded view – rear final drive 21

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

♦ Torque wrench -V.A.G 1332-

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

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

Removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Refer to general repair instructions ⇒ page 5 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unbolt propshaft from rear final drive ⇒ page 15 .
– Remove guard plates (left and right) from rear final drive
-arrows-.
– Unbolt drive shafts (left and right).

– Position engine/gearbox jack -V.A.G 1383 A- with universal

gearbox support -V.A.G 1359/2- under rear final drive.
– Secure rear final drive to universal gearbox support with a
strap.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Remove securing bolts for final drive support -arrows-.

– Remove securing bolts -arrow A- and -arrows B- from cross

member.
Bolt -arrow A- remains in cross member.

– Slightly lower rear final drive.

– Turn rear final drive slightly to the side and pull drive shafts out
of flange shafts alternately on each side.
– Lower rear final drive completely.
Installing rear final drive
Perform installation in reverse sequence of removal. Note the fol‐
lowing:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Turn rear final drive to the side.

– Lift rear final drive and fit drive shafts into flange shafts alter‐
nately on each side.

4. Exploded view – rear final drive 23

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Install securing bolt -arrow A- and tighten lightly to start with.

– Install securing bolts -arrows B-.
– Tighten securing bolts -arrow A- and -arrows B-
⇒ Item 4 (page 21) .

– Tighten securing bolts -arrows- for Protected

final drive support
by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Item 13 (page 21) . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Attach drive shafts ⇒ Rep. Gr. 42 .

– Install guard plates (left and right) on rear final drive -arrows-.
Tightening torque ⇒ Item 11 (page 21) .
– Renew gasket on flange for propshaft and secure propshaft to
rear final drive (markings must face each other ⇒ page 17 ).
– Check gear oil level in rear final drive ⇒ page 20 .
– Install rear section of exhaust system ⇒ Rep. Gr. 26 .

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

5 Renewing flange shaft oil seals

• The oil seals can be only be renewed with the final drive re‐
moved.
⇒ “5.1 Renewing flange shaft oil seal (right-side)”, page 26
⇒ “5.2 Renewing flange shaft oil seal (left-side)”, page 27
⇒ “5.3 Renewing protective ring on flange shaft”, page 29
Special tools and workshop equipment required
♦ Drift -VW 295-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Puller -T10037-

♦ Thrust piece -T40110-

5. Renewing flange shaft oil seals 25

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

♦ Thrust piece -T40111-

♦ Sealing grease -G 052 128 A1-

5.1 Renewing flange shaft oil seal (right-

side)
– Observe the general repair instructions ⇒ page 5 .
– Remove rear final drive ⇒ page 21 .
– Place drip tray underneath.
– Secure puller -T10037- to housing -arrow- and pull out flange
shaft.

– Pry out oil seal with a suitable lever.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Lightly
with lubricate
respect to the outer circumference
correctness ofdocument.
of information in this oil sealCopyright
with gearby AUDIoil.
AG.

– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
– Drive in new seal onto stop (take care to keep seal straight).

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Drive in flange shaft with drift -VW 295- .

– Install rear final drive ⇒ page 23 .
– Check oil level in rear final drive ⇒ page 20 .

5.2 Renewing flange shaft oil seal (left-side)

– Observe the general repair instructions ⇒ page 5 .
– Remove rear final drive ⇒ page 21 .
– Place drip tray underneath.
– Secure puller -T10037- to housing -arrow- and pull out flange
shaft.

– Pry out oil sealpermitted

with aunless
suitable lever.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– 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 seal onto stop (take care to keep seal straight).

5. Renewing flange shaft oil seals 27

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Drive in flange shaft with drift -VW 295- .

– Install rear final drive ⇒ page 23 .
– Check oil level in rear final drive ⇒ page 20 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

5.3 Renewing protective ring on flange shaft

Special tools and work‐
shop equipment re‐
quired
♦ Thrust plate -VW
401-

♦ Thrust plate -VW

402-

♦ Press tool -VW 407-

♦ Tube -32 - 119-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Renewing flange shaft oil seals 29

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

♦ Thrust pad -3062-

♦ -3- Splitter 22...115

mm , e.g. -Kukko
17/2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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- .

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

6 Renewing oil seal for propshaft flange on rear final drive (rear final
drive installed)

Note

Original flange for propshaft must be re-installed.

Special tools and workshop

equipment required
♦ Drive flange installing tool -
VW 391-
♦ Multi-purpose tool -VW Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
771- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Extractor tool -VW 771/37-
♦ Thrust piece -T40112-
♦ Counterhold tool -3028-
♦ Drift sleeve -3143-

Special tools and workshop equipment required

6. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 31
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

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

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

♦ Torque wrench -V.A.G 1576-

♦ Sealing grease -G 052 128 A1-

♦ Locking fluid -AMV 185 101 A1-
♦ 3 bolts (M10 x 25)
Removing
• Rear final drive installed
Refer to general repair instructions ⇒ page 5 .
– Detach propshaft from rear final drive ⇒ page 15 .
– Position engine/gearbox jack -V.A.G 1383 A- with universal
gearbox support -V.A.G 1359/2- under rear final drive.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Remove securing bolts for final drive support -arrows-.

– Carefully lower final drive until flange for propshaft is freely
accessible.

– Mark position of pinion shaft nut relative to pinion shaft

-arrow-.

Measuring dimension "a" and dimension "b"

♦ Distance from flange to pinion shaft = dimension -a-
♦ Distance from flange to pinion shaft nut = dimension -b-
– Note measurements.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fit counterhold tool -3028- to flange for propshaft and screw

off pinion shaft nut.
– 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)

6. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 33
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– 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.

Caution

If you now ascertain that flange for propshaft needs to be re‐

newed, proceed as follows:
♦ Re-install flange for propshaft as described below (but do
not renew oil seal yet)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Remove rear final drive ⇒ page 21 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Renew flange for propshaft and oil seal after measuring
friction torque ⇒ page 36

– Remove 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 seal onto stop (take care to keep seal straight).

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Align mark on flange for propshaft -arrow A- with mark on pin‐

ion shaft -arrow B-.

– Drive flange for propshaft onto pinion shaft.

– Install the originally fitted

Protected by pinion
copyright. shaft
Copying nut (apply
for private locking
or commercial fluid
purposes, - or in whole, is not
in part
AMV 185 101permitted
A1- ) and
unless tighten
authorised to the AG.
by AUDI previously
AUDI AG does marked
not guarantee or accept any liability
position -arrow-withbyrespect
turning the same number of turns as noted
to the correctness of information in this document. Copyright by AUDI AG.

on removal.

Checking dimension “a” and dimension “b”

• The measurements must be the same as noted previously
within a tolerance of ± 0.2 mm.

6. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 35
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Tighten securing bolts -arrows- for final drive support.

♦ Tightening torque ⇒ Item 13 (page 21)
– Install propshaft on rear final drive ⇒ page 17 .
– Check oil level in rear final drive ⇒ page 20 .
– Install rear section of exhaust system ⇒ Rep. Gr. 26 .

6.1 Renewing flange for propshaft and oil seal

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- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Counterhold tool -3028- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Drift sleeve -3143-

Special tools and workshop equipment required

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

♦ Torque wrench -V.A.G 1576-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Bearing preload gauge -VAS 6222-

♦ Sealing grease -G 052 128 A1-

♦ Locking fluid -AMV 185 101 A1-
♦ 2 bolts M8 x 25
– Observe the general repair instructions ⇒ page 5 .
– Remove rear final drive ⇒ page 21 .
– Securing rear final drive to assembly stand

– Measure friction torque before slackening pinion shaft nut.

– Make a note of the measurement.

Caution

The friction torque must be set to this value after renewing the
oil seal.

6. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 37
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– Fit counterhold tool -3028- to flange for propshaft and screw

off pinion shaft nut.
-A- 3 bolts M 8 x 25
-B- Socket (32 mm)

– Secure installing tool -VW 391- with 2 bolts M 8 x 25

-arrows-.
– Pull off flange for propshaft.

– Remove oil seal.

– Clean thread of pinion shaft.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– 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 seal onto stop (take care to keep seal straight).

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤
Rear final drive 08V - Edition 12.2007

– 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 -A-.

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!

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Tighten new pinion shaft nut with torque wrench -V.A.G 1576-
with respect to the correctness of information in this document. Copyright by AUDI AG.

until friction torque measured prior to removal is reached.

– Measure and mark radial run-out at flange for propshaft on

rear final drive ⇒ page 19 .
– Install rear final drive ⇒ page 23 .
– Check oil level in rear final drive ⇒ page 20 .

6. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 39