Service

Workshop Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
Audi A6 2005 ➤
Audi A8 2003 ➤
Rear final drive 0AR
Edition 07.2007

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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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

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
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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 A005AA00120

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Rear final drive identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Audi A4 2001 ▸ – Code letters, allocation, transmission ratios and capacities . . . . . . . . . . 2
1.2 Cabriolet 2003 ▸ – Code letters, allocation, transmission ratios and capacities . . . . . . . . 2
1.3 Audi A6 2005 ▸ – Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . 3
1.4 Audi A8 2003 ▸ – Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . 4
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Jacking mode (vehicles with pneumatic suspension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

1 Exploded view - servicing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Removing and installing propshaft - Audi A4, Audi Cabriolet and Audi A6 . . . . . . . . . . . . 11
1.2 Removing and installing propshaft on Audi A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Detaching and attaching propshaft at rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Measuring and marking radial run-out at flange for propshaft . . . . . . . . . . . . . . . . . . . . . . 27
3 Checking gear oil in rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6 . . . . . . . . . . . . . . 29
4.1 Removing and installing rear final drive on Audi A4, Audi Cabriolet and Audi A6 . . . . . . . . 29
5 Exploded view - rear final drive on Audi A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1 Removing and installing rear final drive on Audi A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Renewing flange shaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 Renewing protective ring on flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) . . . . . . 45
8.1 Renewing protective ring on flange for propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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Contents i
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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ii Contents
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

00 – Technical data
1 Rear final drive identification
The rear final drive 0AR is installed in conjunction with the fol‐
lowing gearbox types:
♦ 6-speed manual gearbox 02X
♦ 6-speed manual gearbox 0A3
♦ Automatic gearbox 09E, four-wheel drive
♦ Automatic gearbox 09L, four-wheel drive
Allocation, Audi A4 2001 >, Cabriolet 2003 > ⇒ page 2
Allocation, Audi A6 2005 > ⇒ page 3
Allocation, Audi A8 2003 > ⇒ page 4
Location on rear final drive
Final drive 0AR -arrow 1-
Code letters and date of manufacture -arrow 2-

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Final drive 0AR -arrow-

Code letters and date of manufacture for rear final drive

Example: HNR 14 04 05
I I I I
Code letters Day Month Year -2005-
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 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 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

1.1 Audi A4 2001 ▸ – Code letters, allocation, transmission ratios and capacities
Rear final drive 0AR
Code letters HNL HNP HNQ
Manufactured from 06.05 11.05 06.05
to
Allocation Engine 2.0 ltr. - 147 kW TFSI 3.0 ltr. -150 kW TDI 1.8 ltr. - 120 kW
3.0 ltr. - 150 kW TDI 4.2 ltr. -253 kW
3.0 ltr. - 171 kW TDI
3.2 ltr. - 188 kW FSI
4.2 ltr. - 253 kW S4
Ratio Final drive 31 : 10 = 3.100 35 : 9 = 3.889 37 : 9 = 4.111
Z2 : Z1
Drive shaft flange ∅ 75.5 mm 75.5 mm 70.7 mm
Capacity 0.9 litres
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 .

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
Rearwithfinal 0ARCopyright by AUDI AG.
respect to the correctness of information in this document.
drive
Code let‐ HNR JKN
ters
Manufac‐ from 06.05 12.07
tured to
Allo‐ En‐ 4.2 ltr. - 309 2.0 ltr. -
cation gin kW RS4 103 kW
e TDI
Ratio Final drive 37 : 9 = 37 :10 =
Z2 : Z1 4.111 3.700
Drive shaft 75.5 mm 75.5 mm
flange ∅
Ca‐ 0.9 litres
pacity
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 .

1.2 Cabriolet 2003 ▸ – Code letters, allocation, transmission ratios and capaci‐
ties
Rear final drive 0AR
Code letters HNL HNP HNR
Manufactured from 06.05 11.05 06.05
to
Allocation Engine 3.0 ltr. - 150 kW TDI 3.0 ltr. - 150 kW TDI 4.2 ltr. - 309 kW
3.0 ltr. - 171 kW TDI 3.0 ltr. - 171 kW TDI RS4
3.2 ltr. - 188 kW FSI 4.2 ltr. - 253 kW S4
4.2 ltr. - 253 kW S4
Ratio Final drive 31 : 10 = 3.100 35 : 9 = 3.889 37 : 9 = 4.111
Z2 : Z1

2 Rep. Gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Rear final drive 0AR

Code letters HNL HNP HNR
Drive shaft flange ∅ 75.5 mm 75.5 mm 75.5 mm
Capacity 0.9 litres
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 .

1.3 Audi A6 2005 ▸ – Code letters, alloca‐

tion, transmission ratios, capacities
Rear final 0AR
drive
Code let‐ HNL HNN HNP
ters
Manufac‐ from 09.05 11.05 11.05
tured to
Allo‐ En‐ 2.7 ltr. - 120 2.7 ltr. - 120 3.0 ltr. -
cation gin kW TDI kW TDI 155 kW
e 2.7 ltr. - 132 2.7 ltr. - 132 TDI
kW TDI kW TDI 3.0 ltr. -
3.0 ltr. - 155 3.0 ltr. - 155 165 kW
kW TDI kW TDI TDI
3.0 ltr. - 171 3.0 ltr. - 165 3.0 ltr. -
kW TDI kW TDI 171 kW
3.2 ltr. - 188 3.0 ltr. - 171 TDI
kW FSI kW TDI
4.2 ltr. - 442 2.8 ltr. - 154
kW FSI kW FSI
3.0 ltr. - 160
kW
3.2 ltr. - 188
kW FSI
4.2 ltr. - 246
kW
4.2 ltr. - 257
kW FSI
5.2 ltr. - 309
kW FSI
5.2 ltr. - 320
kW FSI
Ratio Final 31 : 10 = 32 : 9 = 35 : 9 =
drive 3.100 3.555 3.889
Z2 : Z1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Drive shaft permitted unless75.5 mmby AUDI 75.5
authorised AG. AUDImm AG does75.5 mm or accept any liability
not guarantee
flange ∅ with respect to the correctness of information in this document. Copyright by AUDI AG.

Ca‐ 0.9 litres

pacity
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 .

1. Rear final drive identification 3

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Rear final 0AR

drive
Code let‐ HNR JKN
ters
Manufac‐ from 11.05 12.07
tured to
Allo‐ En‐ 3.0 ltr. - 155 3.0 ltr. -
cation gin kW TDI 155 kW
e 3.0 ltr. - 171 TDI
kW TDI
3.2 ltr. - 188
kW FSI
Ratio Final drive 37 : 9 = 37 : 10
Z2 : Z1 4.111 =3.700
Drive shaft 75.5 mm 75.5 mm
flange ∅
Ca‐ 0.9 litres
pacity
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 .

1.4 Audi A8 2003 ▸ – Code letters, alloca‐

tion, transmission ratios, capacities
Rear final 0AR
drive
Code let‐ HNK HNM
ters
Manufac‐ from 06.05 06.05
tured to
Allo‐ En‐ 3.0 ltr. - 155 3.0 ltr. - 155
cation gin kW TDI kW TDI
e 4.2 ltr. - 235 3.0 ltr. - 171
kW TDI kW TDI
4.2 ltr. - 240 3.2 ltr. - 188
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
kW TDI kW FSI with respect to the correctness of information in this document. Copyright by AUDI AG.
3.7 ltr. - 206 3.2 ltr. - 191
kW kW FSI
4.2 ltr. - 213 4.2 ltr. - 257
kW kW FSI
4.2 ltr. - 246 5.2 ltr. - 331
kW kW FSI
5.2 ltr. - 309 6.0 ltr. - 331
kW FSI kW
5.2 ltr. - 331
kW FSI
6.0 ltr. - 331
kW
Ratio Final 31 : 10 = 32 : 9 =
drive 3.100 3.555
Z2 : Z1
Drive shaft 108 mm 108 mm
flange ∅
Ca‐ 0.9 litres
pacity

4 Rep. Gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Rear final 0AR

drive
Code let‐ HNK HNM
ters
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 .

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.

1. Rear final drive identification 5

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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 - Gearbox
4 - Input shaft (main shaft)
5 - Differential (front)
6 - Front pinion shaft (output
shaft)
7 - Hollow shaft
8 - Torsen differential
9 - Propshaft
10 - Rear pinion shaft
11 - Differential (rear)

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Note

Arrows point in direction of travel

6 Rep. Gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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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2. Transmission layout 7
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

3 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory gearbox repairs. 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 heading “Com‐
ponents” ⇒ page 8 . 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
off the ground) you must first activate the jacking mode ⇒ Rep.
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 28 .
♦ Capacity and specification, Audi A4 2001 ▸ ⇒ page 2
♦ Capacity and specification, Cabriolet 2003 ▸ ⇒ page 2
♦ Capacity and specification, Audi A6 2005 ▸ ⇒ page 3
♦ Capacity and specification, Audi A8 2003 ▸ ⇒ page 4
♦ 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.
O-rings, oil seals and gaskets
♦ Always renew O-rings, oil seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
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surface on the housing or shaft for burrs resulting permitted
from removal
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

or for other signs of damage.

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

♦ 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 28 .
Locking elements

8 Rep. Gr.00 - Technical data

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ 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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3. General repair instructions 9

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

39 – Final drive - rear differential

1 Exploded view - servicing propshaft

Note

♦ Refer to general repair instructions ⇒ page 8 .

♦ 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 thepermitted
stop at theauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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unless
centre joint, but it must not be subjected to force.
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ 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 27 .

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

1 - Rear final drive

❑ Removing and installing
on Audi A4, Audi Cab‐
riolet and Audi A6
⇒ page 29
❑ Removing and installing
on Audi A8
⇒ page 34
2 - Gasket
❑ Renew
❑ Pull off protective foil
❑ Degrease flange shaft
and glue on gasket
3 - Propshaft
❑ Removing and installing
on Audi A4, Audi Cab‐
riolet and Audi A6
⇒ page 11
❑ Removing and installing
on Audi A8
⇒ page 18
4 - Balancing washer
❑ Not fitted on all vehicles
❑ May be fitted between
one socket head bolt
⇒ Item 5 (page 11)
and one lock plate
⇒ Item 6 (page 11) 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 - Au‐

di A4, Audi Cabriolet and Audi A6
Special tools and workshop equipment required
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with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Exploded view - servicing propshaft 11

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ Assembly tool -3139-

♦ Removal lever -80 - 200-

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

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

mounting -V.A.G 1359/2-

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

Removing propshaft on Audi A4, Audi Cabriolet and Audi A6

♦ Please refer to notes ⇒ page 10 .
♦ Repairs on the propshaft should be carried out on a two pillar
hoist.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Audi A4 and Audi Cabriolet

– Remove rear section of exhaust system behind clamps
-arrows- ⇒ Rep. Gr. 26 .

– 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 again and tighten lightly.

Audi A6
– Remove rear cross piece -1-, where fitted.
– Detach heat shield -3- from vehicle underbody -arrows-.

Continued for all vehicles

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

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1. Exploded view - servicing propshaft 13

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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

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

– Remove bolts -arrows- securing centre bearing.

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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– 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- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the propshaft.
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.

Note

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

ted.

Installing propshaft on Audi A4 and Cabriolet and on Audi A6

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 27 , 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.

1. Exploded view - servicing propshaft 15

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– 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.

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

fied torque ⇒ Item 5 (page 11) .
– Use counterhold tool -T10172- with adapters -T10172/5- .

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

⇒ Item 5 (page 11) .
– Use counterhold tool -T10172- with adapters -T10172/5- .
– Remove assembly tool -3139- .

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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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- (M8x30).

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 11)
– 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 11) . The cen‐
tralising lugs on the centre bearing mounting must fit in the
locating holes -arrows-.

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.

1. Exploded view - servicing propshaft 17

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Continued for all vehicles

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

– Where required, secure front exhaust pipes -1- and -2-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Where fitted, secure heat
permitted unlessshield -3-byto
authorised vehicle
AUDI AG. AUDIunderbody
AG does not guarantee or accept any liability
-arrows-. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install rear section of exhaust system -2- ⇒ Rep. Gr. 26 .

– Where fitted, install rear cross piece -1- ⇒ Rep. Gr. 40 .
Tightening torques
Component Nm
Heat shield for propshaft to gearbox 25

1.2 Removing and installing propshaft on

Audi A8
Special tools and workshop equipment required
♦ Assembly tool -3139-

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ 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-

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.

Removing propshaft

Note

♦ Observe notes ⇒ page 10 .

♦ Repairs on the propshaft should be carried out on a two pillar
hoist.

– Disconnect exhaust system at clamps -1- and -2-.

– Remove both tunnel braces -A- and -B-.

– Remove rear section of exhaust system -C- ⇒ Rep. Gr. 26 .

1. Exploded view - servicing propshaft 19

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– Remove heat shield -arrows-.

– Remove main catalytic converters ⇒ 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.

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
– Attach assembly tool -3139- with -3139/4- , and
with respect tighten
to the theof information in this document. Copyright by AUDI AG.
correctness
plastic nuts.

Note

Do not fit assembly tool onto balance plates.

– Remove bolts -arrows- securing centre bearing.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– Unbolt heat shield -A- from gearbox -arrows-.

– 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- .

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.

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

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

Note

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

ted.

Installing propshaft on Audi A8

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

1. Exploded view - servicing propshaft 21

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ 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 27 , 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.

– Bring propshaft
Protected byinto position
copyright. and
Copying fit new
for private bolts atpurposes,
or commercial rear final drive
in part or in whole, is not
-arrows- permitted
and atunless
gearbox.
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.

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

be moved.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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

fied torque ⇒ Item 5 (page 11) .
– Use counterhold tool -T10172- with adapters -T10172/5- .

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

⇒ Item 5 (page 11) .
– Use counterhold tool -T10172- with adapters -T10172/5- .
– Remove assembly tool -3139- .

– Install heat shield -A- -arrows-.

Moving centre bearing to central position:

– Slacken securing bolts for centre bearing slightly.
– Move propshaft forward onto stop and mark position of centre
bearing on body -arrow A-.
– Move propshaft to rear onto stop and mark position of centre
bearing on body -arrow B-.
– Move propshaft to right onto stop and mark position of centre
bearing on body -arrow 1-.
– Move propshaft to left onto stop and mark position of centre
bearing on body -arrow 2-.
– Move propshaft to central position -arrow C- and -arrow 3-.
• The centre bearing must be positioned in central position be‐
tween marks -arrow A- and -arrow B- and between -arrow 1-
and -arrow 2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten securing bolts of centre bearing to torque
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.
⇒ Item 8 (page 11) .

1. Exploded view - servicing propshaft 23

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Continued:
– Install heat shield below centre bearing -arrows-.
– Install exhaust system and perform stress-free alignment ⇒
Rep. Gr. 26 .

– Install both tunnel braces -A- and -B- ⇒ Rep. Gr. 66 .

Tightening torques
Component Nm
Heat shield for propshaft to gearbox 25

1.3 Detaching and attaching propshaft at

rear final drive
Special tools and workshop equipment required
♦ Counterhold tool -T10172- with adapters -T10172/5-

♦ High-temperature grease -G 000 633-

Detaching propshaft from rear final drive
♦ Please refer to notes ⇒ page 10 . 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

♦ Repairs on the propshaft should be carried out on a two pillar

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

hoist.
– Release clamps -1- and -2- and remove rear section of ex‐
haust system ⇒ Rep. Gr. 26 .

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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

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

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.

– 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.
– Bring propshaft into position and fit bolts on CV joints.
– Make sure that the marks on the propshaft flange -arrow A-
and on the rear final drive flange -arrow B- are in line.

1. Exploded view - servicing propshaft 25

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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

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

fied torque ⇒ Item 5 (page 11) .
– 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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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-.
♦ The radial run-out can be measured without removing the rear
final drive.

– Unbolt propshaft from rear final drive ⇒ page 24 .

– Secure measuring equipment to rear final drive with bolt -A-
(M10x30).
– 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.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Mark point of maximum radial

with respect to the run-out
correctnesswith coloured
of information in this dot on Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
document.
outside of flange (corresponding to maximum distance from
axis of rotation).
– Then remove previous marking on flange.
– Attach propshaft ⇒ page 25 .

2. Measuring and marking radial run-out at flange for propshaft 27

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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

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

– Remove screw 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.
• Gear oil specifications: Audi A4 2001 ▸ ⇒ page 2
• Gear oil specifications: Cabriolet 2003 ▸ ⇒ page 2
• Gear oil specifications: Audi A6 2005 ▸ ⇒ page 3
• Gear oil specifications: Audi A8 2003 ▸ ⇒ page 4
– Screw in plug -arrow- and tighten.
Tightening torque: 45 Nm

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

4 Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi
A6

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 29
9 - Drive shaft
♦ Removing and installing ⇒
Rep. Gr. 42
10 - Guard plate
11 - Hexagon socket head
bolts, 25 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - Final
permitted drive support
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.
13 - Hexagon socket head bolts, 40 Nm

4.1 Removing and installing rear final drive

on Audi A4, Audi Cabriolet and Audi A6
Special tools and workshop equipment required

4. Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6 29
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ 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
Refer to general repair instructions ⇒ page 8 .
– Remove rear section of exhaust system behind clamps
-arrows- ⇒ Rep. Gr. 26 .

– Check whether there is a factory marking (coloured dot) 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.
– Unbolt propshaft from rear final drive ⇒ page 24 .

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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– Separate propshaft from rear final drive and tie up to one side
-arrow-.

– 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.

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

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.

4. Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6 31
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– 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 on Audi A4, Audi Cabriolet and Audi A6
Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Turn rear final drive to the side.
– Lift rear final drive and fit drive shafts into flange shafts alter‐
nately on each side.

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

– Install securing bolts -arrows B-.
– Tighten securing bolts -arrow A- and -arrows B-. Tightening
torque ⇒ Item 4 (page 29) .

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 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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

ening torque ⇒ Item 11 (page 29) .

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.

– Attach drive shafts ⇒ Rep. Gr. 42 .

– Install guard plates (left and right) on rear final drive -arrows-.
Tightening torque ⇒ Item 11 (page 29) .
– Renew gasket on flange for propshaft and secure propshaft to
rear final drive (markings must face each other ⇒ page 25 ).
– Check gear oil level in rear final drive ⇒ page 28 .
– Install rear section of exhaust system ⇒ Rep. Gr. 26 .

4. Exploded view - rear final drive on Audi A4, Audi Cabriolet and Audi A6 33
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

5 Exploded view - rear final drive on Audi A8

1 - Subframe
❑ Removing and installing
⇒ Rep. Gr. 42
2 - Hexagon bolt
3 - Washer
4 - Nut, 40 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Self-locking
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
5 - Hexagon socket head bolts,
55 Nm
6 - Rear tunnel brace
7 - Drive shaft
❑ Removing and installing
⇒ Rep. Gr. 42
8 - Heat shield
9 - Bolt with washer, 25 Nm
10 - Final drive support
❑ Note assembly se‐
quence
11 - Hexagon socket head bolt,
40 Nm + tighten 90° (1/4 turn)
further
❑ Renew
12 - Hexagon socket head bolt,
40 Nm + tighten 90° (1/4 turn)
further
❑ Renew
13 - Not fitted
14 - Not fitted
15 - Not fitted
16 - Not fitted
17 - Rear final drive
❑ Removing and installing ⇒ page 34
18 - Nut
❑ Self-locking
❑ Renew
❑ Tightening torque ⇒ Rep. Gr. 42
19 - Washer
20 - Hexagon bolt

5.1 Removing and installing rear final drive

on Audi A8
Special tools and workshop equipment required

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ Torque wrench -V.A.G 1332-

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

port -V.A.G 1359/2-

Removing
Refer to general repair instructions ⇒ page 8 .
– Remove rear section of exhaust system behind clamps -1- and
-2- ⇒ 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.

– 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.

5. Exploded view - rear final drive on Audi A8 35

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– Unbolt propshaft from rear final drive -arrows-.

– Tie up propshaft to side -arrow-.

– Remove heat shields from rear final drive -arrows-.

– Unbolt drive shafts (left and right).

– Position engine and gearbox jack -V.A.G 1383 A- with univer‐

sal support -V.A.G 1359/2- below 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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– Unscrew bolts for final drive support -arrows A and B-.

– Remove bolts -arrows- for rear cross member.

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.

– 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 on Audi A8

Perform installation in reverse sequence of removal. Note the fol‐
lowing:
– Turn final drive to the side.
– Lift rear final drive and fit drive shafts into flange shafts alter‐
nately on each side.

5. Exploded view - rear final drive on Audi A8 37

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– Fit and tighten bolts -arrows-. Tightening torque

⇒ Item 5 (page 34) .

– Fit bolts -A- and -B- and tighten lightly to start with (final drive
support must be in full contact with final drive). First tighten
bolt -A-, then bolts -B-. Tightening torque
⇒ Item 11 (page 34) and ⇒ Item 12 (page 34) .

– Attach drive shafts ⇒ Rep. Gr. 42 .

– Fit heat shields at rear final drive -arrows-. Tightening torque
⇒ Item 9 (page 34) .
– Renew gasket on flange for propshaft and secure propshaft to
rear final drive (markings must face each other ⇒ page 25 ).
– Check gear oil level in rear final drive ⇒ page 28 .
– Install rear section of exhaust system and perform stress-free
alignment ⇒ 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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

6 Renewing flange shaft oil seals

• The oil seals can be only be renewed with the rear final drive
removed.
Special tools and workshop equipment required
♦ Puller -T10037-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Drift -VWpermitted
295- 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.

♦ Thrust piece -T40108-

♦ Sealing grease -G 052 128 A1-

Removing
– Observe the general repair instructions ⇒ page 8 .
– Remove rear final drive
⇒ “4.1 Removing and installing rear final drive on Audi A4, Audi
Cabriolet and Audi A6”, page 29 or
⇒ “5.1 Removing and installing rear final drive on Audi A8”,
page 34 .

6. Renewing flange shaft oil seals 39

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Removing flange shaft (right side)

– Place drip tray underneath.
– Secure puller -T10037- to housing -arrow- and pull out flange
shaft.

Removing flange shaft (left-side)

– Place drip tray underneath.
– Secure puller -T10037- to housing -arrow- and pull out flange
shaft.

– Pry out oil seal with a suitable 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 using thrust piece -T40108- .
Take care to keep seal straight when installing.
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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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 using thrust piece -T40108- .
Take care to keep seal straight when installing.

Installing flange shaft (right and left)

– Drive in flange shaft with drift -VW 295- .
– Install rear final drive.
♦ Installing on A4, Cabriolet and A6 ⇒ page 32
♦ Installing on A8 ⇒ page 37
– Check oil level in rear final drive ⇒ page 28 .

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.

6. Renewing flange shaft oil seals 41

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

7 Renewing protective ring on flange

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

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.

♦ Thrust plate -VW

402-

♦ Press tool -VW 412-

♦ Tube -3146-

7. Renewing protective ring on flange shaft 43

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ -3- Splitter 22...115

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

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

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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

8 Renewing oil seal for propshaft

flange on rear final drive (rear final
drive installed)
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-

♦ Drive flange installing tool -VW 391-

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.

♦ Adapter -VW 771/40- from multi-purpose tool set -VW 771-

♦ Counterhold tool -3028-

8. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 45
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ Extractor tool -T20143-

♦ Thrust piece -T40109-

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.

♦ Sealing grease -G 052 128 A1-

♦ 2 x Hexagon bolts M 8 x 30
♦ Bolts (1x) M 8 x 45
Removing
• Rear final drive installed
Refer to general repair instructions ⇒ page 8 .
– Remove rear section of exhaust system behind clamps
-arrows- ⇒ Rep. Gr. 26 .
– Detach propshaft from rear final drive and tie up ⇒ page 24 .

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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

gearbox support -V.A.G 1359/2- under rear final drive.

Audi A4, Cabriolet and A6

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

Audi A8
– Unscrew bolts for final drive support -arrow A- and
-arrows B-.
Continued for all vehicles
– Carefully lower final drive until flange for propshaft is freely
accessible.

– 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

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.

8. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 47
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

– Mark position of flange -B- for propshaft relative to pinion shaft

-A- -arrow-.

Note

♦ This marking is necessary in order to maintain the original po‐

sition of the coloured dot -C- on the outside of the flange.
♦ The coloured dot -C- marks the point of maximum radial run-
out on the flange (corresponding to maximum distance from
axis of rotation).

– Screw two bolts M 8 x 30 -arrows- into flange.

– Place drip tray underneath.
– Pull off flange for propshaft using drive flange installing tool -
VW 391- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Carefully press seal slightly inwards at top part of outer cir‐
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.
cumference -arrow-.

– The seal is then positioned at an angle. Lever out seal.

Caution

Take care not to damage the contact surface for the oil seal on
the pinion shaft.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

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).

– Position flange for propshaft -B- on pinion shaft -A- so that

markings -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
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
of installing tool with spanner). 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 circlip -arrow-.

8. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 49
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

Audi A4, Cabriolet and A6

– Tighten securing bolts -arrows- for final drive support. Tight‐
ening torque ⇒ Item 13 (page 29) .

Audi A8
– Tighten bolts for final drive support -arrow A- and -arrows B-.
Tightening torque ⇒ Item 11 (page 34) and
⇒ Item 12 (page 34) .
Continued for all vehicles
– Install propshaft on rear final drive ⇒ page 25 .
– Check oil level in rear final drive ⇒ page 28 .
– 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.

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

 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

8.1 Renewing protective ring on flange for

propshaft
Special tools and work‐
shop equipment re‐
quired
♦ Adapter -VW 295 A-

♦ Thrust plate -VW

402-

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.

♦ Press tool -VW 408

A-

♦ Support rails -VW

457-

8. Renewing oil seal for propshaft flange on rear final drive (rear final drive installed) 51
 Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A6 2005 ➤ , Audi A8 20 ...
Rear final drive 0AR - Edition 07.2007

♦ -3- Splitter 22...75

mm , e.g. -Kukko
17/1-

Pressing protective ring

-A- off flange for prop‐
shaft
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

Protected -A- onto
by copyright. flange
Copying for propshaft
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
• The protectivewith
ring -A-tomust
respect engage
the correctness in the annular
of information groove
in this document. on by AUDI AG.
Copyright
the flange ⇒ page 52 .

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