TSB : Driveshaft (A4, Cabrio, A6)

Details

Driveshaft (A4, Cabrio, A6) Special tools, testers and auxiliary items required ^ Assembly tool 3139 ^ Pry lever 80 - 200 ^ Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 Driveshaft (Audi A4 and Cabriolet, Audi A6), removing ^ The driveshaft should only be worked on a two column lift. Audi A4, Audi Cabriolet: - Remove rear part of exhaust system from clamping sleeves - arrows -. - Pry off mountings - A - for heat shield above intermediate bearing. - Remove mounting bolts for intermediate bearing - B -. When doing this, support driveshaft by hand. - Remove heat shield while supporting driveshaft. - Install mounting bolts for intermediate bearing by hand. Audi A6: - If present, remove rear transverse beam - 1 -. - Remove heat shield - 3 - from vehicle floor - arrows -. Continuation for all vehicles: - If present, remove mounting bolts for front exhaust pipes - 1 - and - 2 -. - Remove shielding plate - A - from transmission - arrows -. - Check whether there is a marking (colored marking) on driveshaft and at flange/driveshaft at rear final drive. - If this marking is not present, then mark in color the position of driveshaft flange - arrow A - to rear final drive - arrow B -. - Attach Alignment Fixture - 4W Dr. Shaft 3139 and tighten plastic nuts. Note: ^ Never set alignment fixture on balance plates. - Remove mounting bolts - arrows - for intermediate bearing. - Loosen securing bolts of front driveshaft - arrows -. - Remove driveshaft from transmission and support it using engine/transmission jack V.A.G 1383 A. - Remove mounting bolts - arrows - on rear CV joint and remove driveshaft. Note: ^ Only store and move driveshaft fully extended. Installing driveshaft - Audi A4 and Cabriolet, Audi A6 Installation is in reverse order of removal. Note the following: ^ Remove old and dry high-temperature grease from CV joints and flanges for driveshaft. Fill the exact same amount of new grease G 000 633. ^ Always remove any remaining locking fluid from thread bores in drive flanges for transmission driveshaft and for rear final drive. Cleaning can be performed with a tap. Otherwise, the securing bolts can shear while installing. ^ After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and a mounting bolt may not be reinstalled. ^ Always replace (self-locking) securing bolts for driveshaft. ^ Note installation position of driveshaft: Center CV joint is located behind intermediate bearing in direction facing the rear final drive. ^ Make sure that the markings on flange for driveshaft - arrow A - and for transmission/rear final drive - arrow B - line up. ^ If a new driveshaft is installed and the factory marking on the rear final drive flange is no longer visible, check radial run out at flange/driveshaft and adjust color marking at new driveshaft to new marking at flange/driveshaft. - Replace seals for driveshaft at transmission/rear final drive flange. Remove grease from sealing surfaces and adhere new seals. - Insert driveshaft and install with new bolts for CV joint. - Install mounting bolts - arrows - far enough that intermediate bearing can still be moved. - Tighten bolts - arrows - of driveshaft at rear final drive to tightening torque. - Tighten bolts - arrows - of front driveshaft to tightening torque. - Remove alignment fixture 3139. Audi A4, Audi Cabriolet: - Remove mounting bolts - arrows -. When doing this, driveshaft must be supported by a second technician. - Insert heat shield - 2 -. Continue to support driveshaft while doing this. - Install mounting bolts - 4 - on left and right a few more turns. - Secure heat shield - 2 - on left and right with a bolt - 1 - (M8x30) on intermediate bearing - 3 -. Note: ^ When tightening the combination bolt - 4 -, make sure that centering element - arrow A - is located in the locating hole - arrow B -. - Tighten bolts - 2 - of intermediate bearing for driveshaft on to body free of tension. Torque - Remove bolts - 1 -. - Remove mounting bolts for intermediate bearing - B -. When doing this, support driveshaft by hand. - Insert mounting clips for heat shield. Audi A6: - Tighten bolts of intermediate bearing for driveshaft on to body tightening torque. While doing this, centering elements of intermediate bearing must be located in the locating holes - arrows -. Continuation for all vehicles: - Tighten bolts of shielding plate - A - on to transmission - arrows -. - If present, tighten bolts of front exhaust pipes - 1 - and - 2 -. - If present, tighten bolts of heat shield - 3 - on to vehicle floor - arrows -. - Install rear part of exhaust system - 2 -. Tightening torques