Overview - Output Shaft, Vehicles With Self-Locking Center Differential

Fig 1: Output Shaft, Vehicles With Self-Locking Center Differential Exploded View

Courtesy of AUDI OF AMERICA, LLC

1. Internal Multi-Point Bolt
   • Replace after removing
   • 300 Nm
2. Output Shaft Ball Bearing
   • Bearing "H"
   • Installation position: distance points to the drive wheel for spur gear unit -Item  3-
   • Removing. Refer to Figure.
   • Installing. Refer to Figure.
3. Spur Gear Unit Drive Wheel
   • Installation position: groove from the drive wheel for spur gear unit points to the output shaft ball bearing -Item  2-
   • Removing. Refer to Figure.
   • Installing. Refer to Figure.
4. Circlip
5. Inner Output Shaft Roller Bearing
   • Bearing "N"
   • Removing. Refer to Figure.
   • Installing. Refer to Figure.
6. Bearing Shell
7. Inner Output Shaft
   • Removing. Refer to Inner Output Shaft Roller Bearing, Removing, Vehicles with Self-Locking Center Differential .
   • Installing. Refer to Fig 2.
   • Disassembling and Assembling. Refer to INNER OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING, ONLY VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL .
8. Needle Bearing
   • Bearing "31" and "33"
   • Quantity: 2
9. Circlip
10. 4th Gear
    • Removing. Refer to Figure.
    • Installing. Refer to Figure.
11. 6th Gear
    • Removing. Refer to Figure.
    • Installing. Refer to Figure.
12. Thrust Washer
    • For 2nd gear assembly
13. Inner Race/Needle Bearing
    • For 2nd gear assembly
    • Removing. Refer to Figure.
    • Installing. Refer to Figure.
14. Needle Bearing
    • For 2nd gear assembly
15. 2nd Gear Assembly
16. Synchronization
    • For the 2nd gear assembly / reverse gear assembly
    • Installation position: the bevel of the locking collar -arrow- points to the 2nd gear assembly
    • Overview. Refer to Overview - Synchronization .
    • Press out the synchronizer hub. Refer to Figure.
    • Install the synchronizer hub. Refer to Figure.
17. Reverse Gear Assembly
18. Needle Bearing
    • For reverse gear assembly
19. Inner Race/Needle Bearing
    • For reverse gear assembly
    • Removing. Refer to Figure.
    • Installing. Refer to Figure.
20. Thrust Washer
    • For reverse gear assembly
21. Bearing Bracket
    • With reverse gear intermediate sprocket
    • Overview. Refer to OVERVIEW - BEARING BRACKET .
    • Removing. Refer to Figure.
    • Installing. Refer to Figure.
    • Disassembling and Assembling. Refer to BEARING BRACKET, DISASSEMBLING AND ASSEMBLING .
22. Thrust Washer
    • For 1st Gear Assembly
23. Inner Race/Needle Bearing
    • For 1st Gear Assembly
    • Removing. Refer to Figure.
    • Installing. Refer to Figure.
24. Needle Bearing
    • For 1st Gear Assembly
25. 1st Gear Assembly
26. Synchronization
    • For 1st Gear Assembly / 3rd Gear Assembly
    • Overview. Refer to Overview - Synchronization .
    • Press out the synchronizer hub. Refer to Figure.
    • Install the synchronizer hub. Refer to Figure.
27. 3rd Gear Assembly
28. Needle Bearing
    • For 3rd gear assembly
29. Outer Output Shaft
    • With splines for 5th and 7th gears
    • Removing and Installing. Refer to GEAR SET, DISASSEMBLING AND ASSEMBLING .
    • Disassembling and Assembling. Refer to OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING .
30. Bearing Inner Race
    • Bearing "F"
    • For output shaft roller sleeve
    • Removing. Refer to AWD Vehicles .
    • Installing. Refer to AWD Vehicles .
31. Circlip

Fig 2: Inner Output Shaft Roller Bearing, Removing, Vehicles with Self-Locking Center Differential

Courtesy of AUDI OF AMERICA, LLC