REPLACE SHIFT FORK, 0B0 "quattro ultra"

Special tools and workshop equipment required 

• Gearbox Holder: 2004 

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• Plate: 2004/1 
• Bearing Installer - Carrier Bearing: 3350/1 

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• Bearing Installer - Carrier Bearing: 3350/2 
• Press Piece - Pad: 30 - 555 
  Fig 1: 30-555 Thrust Piece

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• Puller - Two Arm : T10040  with Puller - Two Arm w/Thrust Piece: T10040/2 

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• Alternatively: Extractor Hooks for VAS251001: VAS 251 001/2 
• Counterhold - Kit - Multiple Use: T10172/9 
  Fig 2: Counterhold - Kit - Multiple Use T10172

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Procedure 

-- Drain the gear oil. Refer to GEAR OIL, DRAINING AND FILLING .

-- Remove the rear final drive. Refer to FINAL DRIVE, REMOVING AND INSTALLING .

-- Lay the final drive on a workbench.

-- Remove the All-Wheel Drive Clutch Actuator 2 -V623-. Refer to All-Wheel Drive Clutch Actuator 2 -V623-, REMOVING AND INSTALLING, 0B0 "quattro ultra", 09R "quattro ultra" .

-- Loosen the bolts -1 to 9- and disconnect the housing halves.

• Do not damage sealing surface.

-- Stretch the housing half.

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• 1: Gearbox Holder: 2004 
• 2: Plate: 2004/1 
• 3: Bearing Installer - Carrier Bearing: 3350/1 
• 4: Bearing Installer - Carrier Bearing: 3350/2 
• A: M10x55 bolt
• B: M10x35 bolt with nut
• C: M12x1, 5x35 bolt
• D: M10 washer (quantity: 3)
• Tightening specifications: 40 Nm

-- Pull out the gear carrier -3- using the Puller - Two Arm: T10040  .

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• 1: Puller - Two Arm: T10040  with Puller - Two Arm w/Thrust Piece: T10040/2  or Extractor Hooks for VAS251001: VAS 251 001/2 
• 2: Press Piece - Pad: 30 - 555 

-- Remove the gear carrier -1-, while this, guide out the shift fork out of the clutch module.

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-- Remove the washer -2-.

-- Remove the springs -1-.

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-- Remove the roller sleeves -2-.

Press out the bearing pins.

• A second mechanic is needed to continue removing the driveshaft.

-- Install the M8 collar nut -3- onto the Counterhold - Kit - Multiple Use: T10172/9  -4-.

-- Tension the gear carrier in the vise as shown -1- using the plastic clamping jaws -2-.

-- Position the sleeve -6- from the replacement parts between the shift fork -8-.

-- Press out the bearing pin -5- all the way until the thrust piece stops -4-.

• The bearing pin -5- remains in the shift fork -8- together with the sleeve -6-.

-- Repeat the procedure on the other side.

Replace the shift fork.

-- Replace the parts according to repair kit.

-- Insert the pins -1- into the hole of the gear carrier -arrow A-.

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• The pins have to be easy to move forward and backward -arrow B-.

-- Insert the shift fork -2-, in doing so, pay attention to the right installation position.

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• Flap the latch -1- outward for installation.
• Insert the shift fork -2- into the recess of the gear carrier -arrow-.

-- Insert the pin -3-, in order to secure the -2-.

Press in the bearing pin.

-- Tension the gear carrier -2- and pin -5- as shown into the vise -4-.

-- Push in the pin -5- so far that the it is flush with the inner side of the shift fork -1-.

-- Repeat the procedure on the other side.

-- Check if the shift fork -1- can be swiveled with ease.

Assemble the final drive

-- Grease the bearing bushings -2- slightly and attach.

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• The grease is only used to secure the bearing bushings when installing.
• Commercially available universal grease. Refer to the Parts Information.

-- Insert the springs -1-.

-- Insert the clutch module -3- into the gear carrier. Pay attention that the sleeves -1- engage into the groove of the coupling sleeve -3-.

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-- Insert the shim -3-.

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-- Insert the gear carrier -1- into the housing together with the coupling sleeve. Pay attention that the shock absorber -2- and the centering pin are correctly positioned to the housing -arrow-. If necessary, use a mallet to drive in the gear carrier.

-- Remove the magnet -1-, clean it and re-insert.

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-- Clean any oil and sealant residue off of the housing halves.

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-- Apply the sealant onto the housing halves for the differential as shown.

• Sealant. Refer to the Parts Information

-- Put on the housing halves and tighten the bolts.

• Tightening specification and sequence. Refer to Figure.

-- Install the All-Wheel Drive Clutch Actuator 2 -V623-. Refer to All-Wheel Drive Clutch Actuator 2 -V623-, REMOVING AND INSTALLING, 0B0 "quattro ultra", 09R "quattro ultra" .

-- Install the rear final drive. Refer to FINAL DRIVE, REMOVING AND INSTALLING .

-- Fill the gear oil. Refer to GEAR OIL, DRAINING AND FILLING .