Audi Q7 363 User Manual

Service Training

Audi Q7 - Power Transmission / Transfer Case 0AQ

Self-Study Programme 363

Audi Q7 - Power transmission by the inventor of the quattro®.

The powertrain concept of the Audi Q7 offers impressive performance at high speeds in addition to outstand­ing dynamics, both on and off the road.

The permanent quattro four-wheel drive® with asymmetric, dynamic torque split ensures maximum traction
and cornering stability. These features are essential to good driving dynamics and active motoring safety, par­ticularly when driving on paved roads and at high speeds.

The newly developed transfer case 0AQ is the centrepiece of the power transmission system.

This SSP deals mainly with the design and function of this new development.

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Contents

Introduction

Drive concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Subassemblies overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Brief description of the gearbox

6-speed manual gearbox 08D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6-speed automatic gearbox 0AT / 09D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gear selector mechanism

Automatic gearbox selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Manual gearbox selector mechanism (refer to SSP 299) . . . . . . . . . . . . . . . . . . . . .

Transfer case 0AQ

Design / function of transfer case 0AQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Self-locking centre differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Components overview / design / function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Asymmetric basic torque distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Asymmetric/dynamic torque distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Oil supply / sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Service

Service / special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Useful information

Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

This self-study programme teaches the design and function of new vehicle models, new automotive compo­nents or new technologies.

The self-study programme is not a workshop manual!
All values given are intended as a guideline only, and refer
to the software version valid at the time of publication of the SSP.

Please refer to the relevant service literature for current inspection, adjustment and repair instructions.

NoteReference

Introduction

Drive concept

As an SUV* with excellent on- and off-road
driving dynamics, the Q7 is equipped as standard
with quattro four-wheel drive.

The running gear and the layout of the drive train
sub-assemblies were adopted from the VW Touareg.

This configuration allows the engine to be posi­tioned directly over the front axle. Thus, the step-up
gear and the transfer case migrate more towards the
centre of the vehicle, favouring a well-balanced axle
load distribution beneficial to driving dynamics.

Rear axle differential 0AB

363_002

The sub-assemblies step-up gear, front axle differ­ential and transfer case are independent compo­nents. The powertrain has what is known as a
"modular design".

The advantage of this modular design is that it ena­bles the ground clearance of an off-road vehicle to
be increased.

* SUV = sport utility vehicle

4

One of the primary development goals for the Audi
Q7 was good driving dynamics on paved roads.
A special reduction gear and a mechanical differen­tial lock were dispensed with in favour of the rede­signed transfer case and the newly developed self­locking centre differential.

The self-locking centre differential is already in use
in the Audi RS4 and S4, and features asymmetric/
dynamic torque distribution.

Transfer case 0AQ

Up to 85% of driving torque can be transferred
mechanically, i.e. without EDL engagement, to the
rear axle and up to 65% to the front axle. The new
differential ensures optimal on-road driving dynam­ics.

When wheelspin occurs - off road or on icy surfaces

- the EDL control system engages and provides trac­tion in almost any driving situation.

Step-up gear
Automatic or manual
gearbox

Front axle differential 0AA

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5

Introduction

Sub-assemblies overview

The following gearboxes are used:

Audi Q7 4.2 FSI:

257 kW (350 bhp), 440 Nm

Audi Q7 3.0 TDI:

171 kW (233 bhp), 500 Nm

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Audi Q7 3.6 FSI:

206 kW (280 bhp, 360 Nm)

6-speed automatic gearbox 0AT
(expected SOP: 4th quarter 2006)

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6-speed automatic gearbox 09D

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6-speed manual gearbox 08D/ ML400
(expected SOP: 2nd quarter 2006)

6

The front and rear axle differentials derive from the
VW Touareg. Both differentials are manufactured by
ZF Getriebe GmbH.

Front axle differential 0AA

The left-hand drive flange shaft has been extended
to compensate for the asymmetric installed position
of the front axle differential.

Thus, the additional torque resultant from the drive
torque is transmitted symmetrically to the front
axle. Negative effects on steering are thus elimi­nated.

Rear axle differential 0AB

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Transfer case 0AQ was redesigned for use in the
Audi Q7.
The 0AQ transfer case was developed in conjunction
with, and is manufactured by Borgwarner.

7

Brief description of the gearbox

6-speed manual gearbox 08D...

… is a conventional full synchromesh
countershaft-type gearbox, also known as a "3-shaft
gearbox".

…derives from the VW Touareg, in which it has
already proved successful.

… is used for engines with up to 400 Nm of torque.

The 08D gearbox was developed by, and is manufac­tured by ZF- Getriebe GmbH.

The 1st and 2nd gears are selected using a triple­cone synchroniser.

The 3rd, 4th and reverse gears have a double-cone
synchroniser.

The 5th and 6th gears have a single-cone synchro­niser.

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Reference

For further information on the
08D gearbox, please refer to SSP 299.

8

The 6-speed automatic gearbox 0AT...

… is an electro-hydraulically controlled 6-speed
planetary gearbox (multi-step automatic gearbox)
with hydrodynamic torque converter and slip-con­trolled converter lockup clutch.

The hydraulic control unit (valve body) and the elec­tronic control unit have been combined in a unit,
the so-called mechatronics. The mechatronics are
located in the oil sump.

The 0AT gearbox...

…is a new development for the Audi Q7 optimised
with regard to weight and fuel economy for engines
with up to 400 Nm of torque.

… belongs to the same family as the 6-speed auto­matic gearboxes 09E and 09L

The 0AT gearbox was developed by, and is manufac­tured by ZF- Getriebe GmbH.

Other features:

– Special deep-seated ATF intake point and the

large ATF capacity to ensure proper oil intake
during off-road use.

– Extended gearbox breather pipe to prevent

ingress of water into the gearbox even under
adverse conditions.

– Large-sized torque converter and torque con-

verter lock-up clutch.

– Integration of the gearbox into the immobiliser

system

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Reference

For further information on 6-speed
automatic gearboxes 09E and 09L, please refer
to SSPs 283/284 and SSP 325.

Note

This gearbox will not be available at roll-out.
Further details will be published later in a sepa­rate SSP.

9

Gearbox code

6-speed automatic gearbox 09D…

… is a conventional electro-hydraulically controlled 6­speed planetary gearbox (multi-step automatic gear­box) with hydrodynamic torque converter and slip­controlled converter lockup clutch.

The hydraulic control unit (valve body) is located in
the oil sump, while the electronic control unit is
accommodated externally in the vehicle interior
(under the right-hand front seat).

The 09D gearbox...

…derives from the VW Touareg, in which it has
already proved successful.

… is used for engines with up to 750 Nm of torque.

… belongs to the same family as the 6-speed auto­matic gearbox 09G (see SSP 291)

The 09D gearbox was developed by, and is manufac­tured by Japanese gearbox manufacturer AISIN AW
CO., LTD.

Other features:

– Special deep-seated ATF intake point and the

large ATF capacity to ensure proper oil intake
during off-road use.

– Extended gearbox breather pipe to prevent

ingress of water into the gearbox even under
adverse conditions.

– Large-sized torque converter and torque con-

verter lock-up clutch.

10

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Reference

For further information on 6-speed
automatic
gearbox 09G, please refer to SSP 291.

Gear selector mechanism

Automatic gearbox selector mechanism

The design and function of the gear selector mecha­nism in the Q7 are largely identical to that of the
gear selector mechanism used in the Audi A6`05.
The differences the gear selector mechanism used
in the Audi A6`05 are listed below.

The gear selector mechanism can be removed vehi­cle interior for repairs (e.g. to replace microswitch
F305).

When the gear selector mechanism is replaced, the
selector housing (installed from the exterior)
remains installed in the vehicle. Only the gear selec­tor mechanism function unit need be replaced.

Selector lever position indicator unit Y26

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Gear selector mecha­nism function unit

Connector B
(4 pin to vehicle wiring loom/gearbox)

Funnel/guide

The funnel makes it easier to
emergency-release the P-lock

Connector housing

Connector A
(10-pin to vehicle wir­ing loom/ gearbox)

Selector lever sensors
control unit J587 with
tiptronic switch F189

Connector C (10-pin
to display unit Y26)

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Reference

For further information on the
gear selector mechanism used in the Audi
A6’05, please refer to SSPs 325 and 283.

11

Gear selector mechanism

P/R/N/ D/ S s ignal

The selector lever sensors control unit J587 is
responsible only for acquisition of the signals for
the tiptronic function (tiptronic switch F189) and
activation of the selector lever position indicator
unit Y26. The Hall sensors used previously to deter­mine the selector lever position for activating the
display unit Y26 are no longer needed. Information
on selector lever position (P/R/N/D/S signal) is now
supplied directly to the selector lever sensors con­trol unit by the gearbox control unit in the form of a
frequency-modulated square-wave signal (FMR sig­nal). The selector lever sensors control unit then
activates the corresponding LEDs on display unit
Y26.

Function diagram of the gear selector mechanism with 09D gearbox

A defined signal frequency is assigned to each
selector lever position (see DSO images).
The selector lever sensors control unit evaluates the
signal and activates the corresponding LED on dis­play unit Y26 (earth activation).

The advantages of this new feature are:

– Synchronous indication of selector lever position

in the dash panel insert and on the selector lever.

– Cost savings through simplification of the selec-

tor lever sensors control unit J587 (elimination of
additional Hall sensors).

Gear selector mechanism

F189 Tiptron ic switch
F305 Gear selector position P switch
F189 Tiptron ic switch
J587 Selector lever sensors control unit
N110 Selector lever lock solenoid
Y26 Selector lever position indicator unit

P/R /N/ D/S sig nal

tiptronic signal

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12

DSO images of P/R/N/D/S signals

DSO connection:
– black probe tip, Pin 6*
– red probe tip, Pin 9*

* Pin to connector A or test adapter V.A.G. 1598/42

Test equipment:
– V.A.G 1598/54 with
– V.A.G 1598/42
– VAS 5051

Test conditions:
– Ignition "ON"

Selector lever positions

P

R

N

D

S

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13

Gear selector mechanism

tiptronic signal

The information on selector lever in tiptronic gate,
selector lever in Tip+ or selector lever in Tip- is
transmitted to the gearbox control unit in the form
of a frequency-modulated square-wave signal (FMR
signal) along a discrete line (see DSO images).

Advantages of this new feature:

– Higher operational reliability - only one line is

required to the control unit (instead of three),
hence there are fewer potential sources of fault.

– Better self-diagnostics.

Reference

The signals and from to the gear selector mecha­nism can be tested by using test adapter V.A.G.

1598/54 in combination with test box V.A.G. 1598/42.

The signals to and from 09D gearbox can be tested
by using test adapter V.A.G. 1598/48 in combination
with test box V.A.G. 1598/42.

The signals to and from the 0AT gearbox can be
tested by using test adapter V.A.G. 1598/40 in com­bination with test box V.A.G. 1598/14.

For further information on the tiptronic signal
and the tiptronic switch F189, please refer to
SSP 291, from p. 50).
Apart from the different signal waveform, the
selector mechanism has the same basic funtion
as the selector mechanism used in the
Audi A3‘04.

14

DSO images of the tiptronic signal

DSO connection:
– black probe tip, Pin 6*
– red probe tip, Pin 3*

* Pin to connector A or test adapter V.A.G. 1598/42

Test equipment:
– V.A.G 1598/54 with
– V.A.G 1598/42
– VAS 5051

Test conditions:
– Ignition "ON"

Selector lever positions

P/R /N /D/ S

tiptronic gate

tiptronic Tip +

tiptronic Tip -

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15

Transfer case 0AQ

Tra ns fe r ca se 0A Q

The development goal for the new transfer case 0AQ
was to design a function and weight optimised
gearbox that underscores the sporty and agile char­acter of the Q7.

Despite the lack of a reduction step, the vehicle
should have sufficient traction during off-road use
to meet the requirements of an off-road vehicle.

Transfer case 0AQ has the following outstanding
features:

– Latest differential generation, with asymmetric/

dynamic torque distribution

– Unlimited compatibility with all vehicle dynamics

control systems of the ESP

– Fully mechanical system with highreliability

– Designed for engines with up to 750 Nm of torque

– Weighing only approx. 31 kg, it has an exception-

ally low power-to-weight ratio

– Maintenance-free lifetime lubricated gearbox

Differential

Oil pan

Output to the rear

Chain drive

Input shaft

Output to the front

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16

Design / function

The transfer case attaches directly to the respective
automatic or manual gearbox. Three different
"lengths of neck" compensate for the different gear­box lengths.
The input shaft, designed as a hollow shaft, trans­mits the engine torque to the differential. The differ­ential equalises differences in speed between the
axles and distributes the driving torque.

Cutaway view of transfer case

Chain sprocket

Input shaft

Drive power is transmitted to the rear axle by the
differential via the output shaft, which is aligned
coaxially to the input shaft. The front axle torque is
transmitted to the upper chain sprocket. The chain
sprocket is rotatably mounted on the upper output
shaft and drives the lower chain sprocket by means
of a chain.
The lower chain sprocket is attached non-rotatably
to the flange shaft and acts as the output to the
front axle differential.

Neck length

Flange shaft
(rear axle drive)

Chain

Chain sprocket

Input shaft

Differential (self-locking
centre differential)

Flange shaft
(front axle drive)

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17

Transfer caseTransfer case 0AQ

Self-locking centre differential

Introduction

The newly developed 3rd generation centre differ­ential is used in the Q7.
As with its predecessors, it is designed as a self­locking differential. The asymmetric/dynamic torque
distribution is a new feature.
The self-locking centre differential is designed as a
planetary gear.

An asymmetric basic torque distribution of 42% to
the front axle and 58% to the rear axle is ideal from
the viewpoint of well-balanced driving dynamics.

A friction torque proportional to the driving torque
is generated in the differential. This in turn pro­duces a locking torque. The locking torque and the
basic torque distribution result from the torque dis­tribution to the axles.

Driving torque [%]

100 %

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100 %

Torque distribution range, rear axle

80

Torque distribution range, front axle

58

42

20

0

23 %

60 %

77 %

40 %

80

58

42

20

0

Max. torque distribution to rear axle (without EDL control system)

Max. torque distribution to front axle (without EDL control system)

18

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Components overview

Chain sprocket
to front axle

Input shaft
(to rear axle)

Planet carrier

Low-friction
bearing

Friction disc

Sun gear/front axle

6 planet gears

Friction disc

Ring gear

Drive hub /rear axle

Friction discs

Differential housing

Oilway

Bearing bush

Input shaft

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19

Transfer caseTransfer case 0AQ

Design / function

The basic design of the self-locking centre
differential is identical to that of a simple planet
gear train with sun gear, planet gears, planet carrier
and ring gear. The planet gears are mounted on the
planet carrier. The driving torque is transmitted via
the planet carrier.

Driving torque
to front axle

The planet gears engage between the sun gear and
the ring gear. The ring gear connects to the rear axle
drive. The sun gear connects to the front axle drive.

Planet carrier

Planet gear

Input torque

Driving torque

to rear axle

Sun gear/front axle

Friction discs

Ring gear

Drive hub/rear axle

Differential housing

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20

Asymmetric basic torque distribution

The asymmetric basic torque distribution of 42:58
(front axle/rear axle) results from the different pitch
circle diameters of the sun gear (drive to front axle)
and the ring gear (drive to rear axle).

Input torque

1 = small pitch circle diameter = short lever arm =

low torque (front axle).

2 = large pitch circle diameter = long lever arm =
high torque (rear axle)

Planet carrier

Planet gear

Drive hub/rear axle

Pitch circle diameter

Lever arm

Sun gear/
front axle

Ring gear

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21

Transfer caseTransfer case 0AQ

Asymmetric/dynamic torque distribution

In addition to the asymmetric basic torque distribu­tion of 42:58, a friction torque proportional to the
driving torque is generated in the differential result­ing in a corresponding locking torque.
Locking torque plus basic torque distribution is the
determining factor for the maximum torque distri­bution to the axles.

100 %

EDL

Operating
range
Differential

Front axle
torque

80

60

42

Basically, the centre differential responds to
changes in torque at the axles.
If an axle loses traction, the driving torque is redi­rected instantaneously to the other axle within the
torque distribution limits.

If the working limits of the centre differential are
exceeded, the EDL control engages and provides
forward traction.

0

yellow - orange:
low coefficient of friction
= snow and ice

green:
High coefficients of friction
= dry and wet

20

40

58

Rear axle
torque

Basic torque
distribution

20

EDL

0

Asymmetric/dynamic torque distribution in the self-locking centre differential (under throttle)

A self-locking centre differential is characterised by
four operating states: Maximum distribution to front
axle and maximum distribution to rear axle while
driving under throttle and while coasting (overrun).

80

100 %

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These four operating states are characterised by
four locking ratios, which can be configured differ­ently.

22

Asymmetric/dynamic torque distribution

The gears of the differential have a defined helical­cut gear form.
Thus, the driving torque produces an axial force
which acts upon the gears, which, in turn, act upon
various friction discs and generate friction.
The friction, in turn, produces the desired lock-up
effect.

Lock-up effect

Lock-up effect
under throttle

under throttle

The magnitude of the lock-up effect is defined by
the locking ratio. The locking ratio by is the factor*
by which the driving torque is transmitted to the
axle which can transmit the greater driving torque.

* number or quantity that is multiplied by another

(multiplicand).

= axial force under

= axial force under throttle

Lock-up effect
while coasting

Helical spline, used to increase

Helical spline, used to increase
frictional force by means of

frictional force by means of
additional friction discs

additional friction discs

= axial force while coasting

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23

Transfer caseTransfer case 0AQ

Example of dynamic torque distribution

In the following example, it is explained how the Q7
responds to changing road conditions.
The torque distribution of a vehicle with an open
centre differential (without lock-up effect) is shown
on the next page as a comparison.

Audi Q7 self-locking centre differential: traction limit* icy surface 250 Nm

t1 t2 t3 t4

1000

800

600

Torqu e [ N m]

400

In both cases, the basic torque distribution is 42% to
the front axle and 58% to the rear axle.

200

0

t1 t2 t3 t4

Driving torque 1000 Nm (constant)

Forward traction

In this example, the Q7 passes over a small
patch of ice (driving conditions t2 and t3) under
constant driving power. The traction limit* is
assumed to be 250Nm per axle. The total driving
torque (t1 and t4) is 1000 Nm.
When the vehicle passes over a patch of ice (t2), the
front axle loses traction, thus reducing the driving
torqueto the traction limit* of 250 Nm. Due to the
lock-up effect of the differential, the driving torque
distributed to the rear axle increases simultane­ously to 750 Nm. As the torque distribution is within
the torque distribution range, no speed differential
occurs between the axles.

Rear axle torque

Front axle torque

EDL braking torque

100% of engine power is converted to forward trac­tion; the EDL control does not have to take counter­measures. At time t the front axle has already
passed over the patch of ice. Now the rear axle now
has to deal with the reduced friction and can only
transfer 250 Nm of torque. To ensure optimal trac­tion at the front axle, the EDL control now comes to
the assistance of the front axle. 85% of engine power
is converted to forward traction.

* maximum amount of torque transferable to an axle

on the patch of ice

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24

Example of static torque distribution

Like in the example on the previous page, a vehicle
drives over a patch of ice with the centre differential
open under the same marginal conditions (total
driving torque 1000 Nm, traction limit* of icy sur­face 250Nm/ axle).

Vehicle with open centre differential, torque split 42/58 traction limit* of icy surface 250 Nm

t1 t2 t3 t4

1000

800

600

Torq u e [ N m ]

400

The torque distribution is identical: 42% to the front
axle and 58% to the rear axle.

200

0

t1 t2 t3 t4

Driving torque 1000 Nm (constant)

Forward traction

The front axle initially loses traction (t2). The EDL
control must take countermeasures in order to
maintain the torque to the axle with the higher coef­ficient of friction (rear axle). 17% of engine power is
redirected away from the front axle, thus reducing
forward traction to the same extent.

Rear axle torque

Front axle torque

EDL braking torque

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If the rear axle passes over the patch of ice at time
t3, the EDL control has to apply additional counter­measures to prevent wheelspin from occurring. The
loss of forward traction is now 33%.

* maximum amount of torque transferable to an axle

on the patch of ice

25

Transfer caseTransfer case 0AQ

The chain drive

The chain drive transmits the driving torque to the
front axle. A specially developed "gear chain" with
associated chain sprockets is used.

The chain drive in the 0AQ transfer case has the fol­lowing features:

– High transferable torque
– Constant speed
– Smooth running
– Maintenance free
– High efficiency

Attention must be paid to the
direction of installation when fit­ting the chain. The chain must be
fitted so that the colour-coded
chain link plates are counter to
the direction of travel, as shown
in the illustration.

The special shape of the link plate ensures that the chain runs
smoothly even at high chain speeds.
The layout of the chain link plates, with two different tooth
flanks and the relatively high, uneven number of teeth on the
sprockets, provides a marked improvement in acoustic quality.

26

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Design and function of the gear chain

The gear chain consists of the juxtaposed chain link
plates which are continuously joined by two cradle
pins. The lateral chain link plates ensure that the
chain runs true.

Guide

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This is how it works:

Each cradle pin is attached non-rotatably to a row of
link plates. Two cradle pins form a so-called cradle­type joint.

As the chain curves around the sprocket, the chain
links roll off the cradle pins. Thus, the chain curves
around the sprocket almost without producing any
friction.

Despite high torque and continuous operation, wear
is reduced to a minimum and efficiency isincreased.

The chain drive is designed to last the service life of
the vehicle.

Straight chain

Chain link plates

Curved chain

Cradle pins/
cradle-type joint

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27

Transfer caseTransfer case 0AQ

Lubrication

The design of the 0AQ transfer case allows the use
of automatic transmission fluid (ATF) for lubrication
purposes.

ATF is notable for its low and constant viscosity
over a large temperature range.

The vehicle is lifetime lubricated with ATF.

Chain link plate

The installation position of the transfer case as well
as the implementation of a low oil level requires
that special measures be taken with regard to lubri­cation of the differential and the overhead lubrica­tion points.

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28

This is how it works:

The upper shafts and the differential are oiled using
an oil pan and directional oilways.

During vehicle operation, the chain delivers the oil
upwards where it is skimmed off by the oil pan.
The oil flows along an elaborate oilway into the dif­ferential and to the input shaft bearing. This
ensures sufficient oil delivery even when driving at
walking speed. The system also operates when the
vehicle is reversing.

A circular "oil ring" forms in the differential due to
the centrifugal force acting upon the oil. When the
vehicle is stationary, this oil ring collapses and lubri­cates the inner lubrication points.

The differential housing is designed in such a way
that a certain amount of oil remains when the vehi­cle is at a standstill. This ensures that the system is
always lubricated properly when driving away.

Oil pan with oilway

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Oil level/oil volume

The lubrication concept described above allows a
low oil level to be maintained and makes it possible
to dispense with forced oil pump lubrication.
This helps to reduce churning losses and to
increase gearbox efficiency.

Note

When repairing the transfer case, attention must
be paid to contamination of the oil pan. The oil­way must be cleaned as required.

29

Transfer caseTransfer case 0AQ

Oil supply / sealing

In adverse offroad conditions, special demands
are made of the sealing of the front axle differen­tial, as well as the rear axle differential and the
transfer case flange shafts. This is why shaft oil
seals with special dust and moisture seals are
used.

The sealing of the flange shafts is shown here
using the 0AQ transfer case as an example.

Shaft oil seal B

Shaft oil seal A

A press-fitted protective ring on the flange shaft
acts as a "deflector ring" and helps to keep dirt and
water away from the lip seals during vehicle opera­tion.

Shaft oil seal C

Prot ect ive ri ng

Outer lip
seals

Oil lip seal

363_038

The outer lip seals help to prevent dust and mois­ture coming into contact with the oil lip seal and its
liner.

30

Service / special tools

Service

To avoid having to replace shaft oil seals shafts or
flange shafts, the shaft oil seals must be press-fitted
more deeply than in series production.

Shaft oil seal A
Series production > press-fitted flush

363_047

Shaft oil seal B
Series production > defined measurement

As a result, the lip seal of the shaft oil seal runs on a
new liner. This ensures less load on the sensitive
lip seal, which, in turn, extends seal life and
improves sealing performance.

Service > press-fitted to the limit.

Pressing tool
T 40115

363_048

Service > defined deeper measurement

363_049

Shaft oil seal C
Series production > defined measurement

363_051 363_052

Pressing tool
T 40113

363_050

Service > defined deeper measurement

Pressi ng tool
T 40114

31

Useful information

Operating instructions

– The self-locking centre differential cannot be

compared to a 100% mechanical differential lock.
If an axle or a wheel begins to spin, no drive is
provided until the EDL control (electronic differ­ential lock) engages.

– The EDL control engages as of a defined speed

difference between the wheels. Throttle must be
applied until the EDL control builds up additional
torque by means of brake application. This addi­tional torque will then be available to the oppo­site wheel. The self-locking centre differential
assists the EDL control by transmitting additional
braking torque to the other axle, where possible.
To prevent overheating of the brake due to pro­longed braking intervention by the EDL, the EDL
will be deactivated as of a max. brake disc tem­perature calculated by the ESP control unit.

– The self-locking centre differential will become

damaged if the system constantly has to equalise
the speeds of the front and rear axles in combi­nation with a high engine load.

– If one of the two prop shafts is removed, no drive

will be available.

– Snow chains may only be fitted to the rear

wheels.

Reference

For further information on the EDL
control, please refer to the section on the
"Offroad mode"

363_040

363_039

32

Electronic Differential Lock EDL

One of the main priorities for the setup of electronic
differential locks which work by braking interven­tion (EDL) is the build-up of a locking torque with a
minimum of wheel slip.

On introduction of the EDL, the wheel speed control
parameters were the main consideration. To protect
the engine against stalling due to brake application,
relatively high wheel differential speeds were nec­essary.
Engagement of the EDL control was at a defined
wheel differential speed in dependence on the vehi­cle's road speed.

Since the introduction of the ESP, engagement of the
EDL control is based on a so-called torque balance.
The brake force to be applied is determined by making
allowance for available engine torque and the amount
of torque transferable to the individual wheels.

The following rule generally applies here:
If a high engine torque is available, the EDL can engage
at lower wheel differential speeds than at a low engine
torque.

The EDL can engage up to a speed of 100 kph.

Reference

For further information, please refer to
SSP 241

Offroad mode

The ESP Offroad mode can be activated, as required,
by pressing the ESP button.

The purpose of the ESP Offroad mode is to improve
ESP, TCS, ABS and EDL performance on loose sur­faces (offroad) and to provide the driver with opti­mum deceleration and traction.

Special auxiliary functions such as deactivation of
the trailer stabilisation system, a special "ABS for
reversing", and the "downhill assist" function assist
the driver in challenging terrain or on loose sur­faces.

In Offroad mode, the EDL activation threshold is
reduced in order to optimise traction. Thus, the EDL
engages even at a low wheel speed differential.

Reference

For further information on the Offroad mode,
please refer to SSP 262

33

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35

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Technical specifications
subject to change without
notice.

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AUDI AG
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Fax [phone]

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Technical status: 11/05

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