Page 32 of 38
34-83
- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear), do
this by moving two selector plates (arrows).
- Tighten multi-point socket head bolt to 150 Nm.
- Unclip cover -3- for oil collector from oil collector -1- at longer end with
a screwdriver and remove magnet -2-.
4 - O-ring
5 - Positioning segment
- Clean oil collector.
- Assemble oil collector.
Pa
ge 32 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5
Page 33 of 38
34-84
- Guide oil collector from interior of end cover with support arm leading
through hole of end cover (arrow), until O-ring can be fitted from
outside onto oil collector.
- Lightly oil new O-ring and fit.
- Insert oil tube of oil collector into input shaft.
- Turn oil collector until the positioning segment is located in the
machined recess of the end cover (arrow).
- Press in oil collector onto stop.
- Slide assembly sleeve, Part No. 01E 311 120, onto selector shaft.
- Check neutral position of followers.
Selector gates must align.
Pa
ge 33 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5
Page 34 of 38
34-85
- Install complete selector shaft.
- Screw locking bolts -A- for selector shaft into transmission housing.
- Aluminium and steel bolts must not be interchanged when installing.
Tightening torques: for aluminium locking bolts = 50 Nm, and for steel
locking bolts = 70 Nm.
- Lightly oil new O-ring for cover for selector shaft and fit.
- Fit cover for selector shaft.
- Apply sealing paste AMV 188 000 02 to bolts -B- (Qty. 3) before
installing and tighten.
- Slide Torsen differential onto splines of hollow shaft.
Parts catalog - Press Torsen differential in direction of arrow, and measure distance
between top edge of bolted end cover and front edge of outer race of
ball bearing for Torsen differential.
- Determine required shim(s) from following table.
Pa
ge 34 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5
Page 37 of 38
34-87
- Insert spring plate -C- into bearing housing.
Installation position: larger diameter (concave side) towards the shims.
- Fit shims -B- as determined in table.
- Fit spring -A- to end of drive flange.
- Lightly oil new O-ring for bearing housing and fit.
- Oil small needle bearing in drive pinion.
- Insert complete bearing housing and pull home evenly.
- Tighten bearing housing using diagonal sequence.
- Fill new seal for drive axle between sealing lip and dust lip with sealing
grease G52 128 A1.
- Pull a thin protective hose tightly onto splines of input shaft.
- Drive on seal for input shaft.
Pressing-in depth (factory): 3.5 mm
Pressing in depth (repairs): 4.5 mm
Pa
ge 37 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5
Page 38 of 38
34-88
- Remove protective hose.
- Install release bearing, clutch release lever and
guide sleeve from Page 30
-27
.
- Check that transmission can be shifted through
all gears.
- Fit connecting rod.
- Check oil level in transmission Page 34
-39
.
Pa
ge 38 of 38 Bearin
g housin
g, Torsen differential, end cover, internal selector mechanism, in
put shaft, drive
pinion and hollow shaft, rem...
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM03.34.5
