Audi TT 68 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi A3 2004 ➤
Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY
Edition 06.2009
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
39 - Final drive - rear differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005AA00320
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Rear final drive identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Audi A3 2004 ▸ – Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . 3
2.1 Audi A3 with rear final drive 02D/0AV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Audi A3 with rear final drive 0BR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Audi TT 2007▸ – Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . 7
3.1 Audi TT with rear final drive 02D/0AV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Audi TT with rear final drive 0BR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Audi TT RS with rear final drive 0BY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Gear oil and oil for Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Safety precautions for Audi TT and Audi A3 Cabriolet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Safety precautions for Audi A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1 Exploded view – propshaft with detachable centre bearing (up to 05.07) . . . . . . . . . . . . . . 19
2 Removing propshaft with detachable centre bearing (up to 05.07) . . . . . . . . . . . . . . . . . . 27
2.1 Installing propshaft with detachable centre bearing (up to 05.07) . . . . . . . . . . . . . . . . . . . . 30
3 Exploded view – propshaft with non-detachable centre bearing (from 05.07 onwards) . . . . 34
3.1 Removing propshaft with non-detachable centre bearing (from 05.07 onwards) . . . . . . . . 35
3.2 Installing propshaft with non-detachable centre bearing (from 05.07 onwards) . . . . . . . . . . 40
4 Exploded view - propshaft (Audi TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1 Removing and installing propshaft (Audi TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Removing and installing flexible coupling (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Connecting vehicle diagnostic, testing and information system VAS 5051B and checking
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7 Checking function of Haldex coupling, rear final drive “02D/0AV” . . . . . . . . . . . . . . . . . . . . 54
7.1 Final drive“02D/0AV” – Checking function of open Haldex coupling on vehicles with manual
gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2 Final drive“02D/0AV” – Checking function of closed Haldex coupling on vehicles with manual
gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.3 Final drive“02D/0AV” – Checking function of open Haldex coupling on vehicles with dual
clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.4 Final drive“02D/0AV” – Checking function of closed Haldex coupling on vehicles with dual
clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8 Checking function of Haldex coupling, rear final drive “0BR” and “0BY” . . . . . . . . . . . . . . 58
9 Electrical and electronic components and fitting locations, rear final drive “02D/0AV” . . . . 59
10 Exploded view – removing and installing four-wheel drive control unit J492 , rear final drive
“02D/0AV” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.1 Removing and installing four-wheel drive control unit J492 , rear final drive “02D/0AV” . . 62
11 Electrical and electronic components and fitting locations, rear final drive “0BR” and “0BY”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
12 Exploded view – removing and installing four-wheel drive control unit J492 , rear final drive
0BD and 0BY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12.1 Removing and installing four-wheel drive control unit J492 . . . . . . . . . . . . . . . . . . . . . . . . 68
13 Exploded view - removing and installing Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 71
13.1 Removing and installing Haldex coupling (with final drive installed) . . . . . . . . . . . . . . . . . . 71
Contents i
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
14 Exploded view – dismantling and assembling Haldex coupling, rear final drive “02D/0AV”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
14.1 Removing and installing oil filter for Haldex coupling, final drive “02D/0AV” . . . . . . . . . . . . 77
14.2 Removing and installing Haldex coupling pump V181 , final drive “02D/0AV” . . . . . . . . . . 78
14.3 Renewing grooved ball bearing for Haldex coupling, final drive “02D/0AV” . . . . . . . . . . . . 82
15 Exploded view – dismantling and assembling Haldex coupling, rear final drive “0BR/0BY”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
15.1 Removing and installing Haldex coupling pump V181 , final drive “0BR/0BY” . . . . . . . . . . 89
16 Renewing oil seal for propshaft flange at rear final drive - final drive remains installed . . . . 93
17 Exploded view – Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . 96
17.1 Removing rear final drive (not TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
17.2 Installing rear final drive (not TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
18 Removing and installing rear final drive (Audi TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
19 Renewing bonded rubber bushes in rear final drive - exploded view . . . . . . . . . . . . . . . . . . 107
20 Renewing flange shaft oil seals (right and left) - rear final drive remains installed . . . . . . . . 112
21 Checking oil level in Haldex coupling and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
21.1 Checking oil level in Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
21.2 Topping up oil in Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
22 Renewing high performance oil for Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
23 Checking gear oil in rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
23.1 Checking gear oil level in rear final drive “02D/0AV” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
23.2 Checking gear oil level in rear final drive “0BR” and “0BY” . . . . . . . . . . . . . . . . . . . . . . . . 123
ii Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
00 – Technical data
1 Rear final drive identification
Note
♦
The “Haldex coupling” is incorporated in the final drive.
♦
The final drive and the “Haldex coupling” have separate oil
circuits.
♦
The final drive units “02D” and “0AV” are equipped with the
“Haldex coupling 2”. Identification ⇒ page 1 and
⇒ page 2 .
♦
Final drive units “0BR” and “0BY” are equipped with the “Hal‐
dex coupling 4”. Identification ⇒ page 2 .
Rear final drive units 02D, 0AV, 0BR and 0BY are fitted in con‐
junction with the following gearboxes:
♦ 6-speed manual gearbox 02Q, four-wheel drive
♦ 6-speed manual gearbox 0A6, four-wheel drive
♦ Direct shift gearbox 02E, four-wheel drive
Rear final drive allocation
♦ ⇒ “2 Audi A3 2004 ▸ – Code letters, allocation, transmission
ratios, capacities”, page 3
♦ ⇒ “3 Audi TT 2007▸ – Code letters, allocation, transmission
ratios, capacities”, page 7
Rear final drive -02D-
Audi A3 2004 ➤ , Audi TT 2007 ➤
Note
♦
The identification -arrow- on the underside of the final drive
unit indicates which final drive version is installed.
♦
In this example: “Rear final drive 02D”
1. Rear final drive identification 1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Example of identification markings on final drive “02D”
-Arrow A- Part number of final drive
-Arrow B- Code letters of final drive
-Arrow C- Production date of final drive
Note
If the code letters -arrow B- are not shown, the unit can be iden‐
tified via the Part No. -arrow A- ⇒ Electronic parts catalogue .
Example:
02D.
HEZ 12 01 04
525.010.AQ
I I I I I
I I I I I
Part No. Code let‐
ters
Day Month Year of manufacture
-2004-
Additional data are manufacture-related.
Example of identification markings on rear final drive “0AV”
-Arrow A- Part number of final drive
-Arrow B- Code letters of final drive
♦ If the code letters are not shown, the unit can be identified via
the Part No. ⇒ Electronic parts catalogue .
-Arrow C- Production date of final drive
Example:
HHJ 09 08 05
I I I I
I I I I
Code letters Day Month Year of manufacture
-2005-
Additional data are manufacture-related.
Rear final drive “0BR” or “0BY”
Note
♦
The identification -arrow- on the underside of the final drive
unit indicates which final drive version is installed.
♦
For further explanation of the identification markings on the
underside of the final drive ⇒ page 2 .
2 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
2 Audi A3 2004 ▸ – Code letters, allo‐
cation, transmission ratios, capaci‐
ties
⇒ “2.1 Audi A3 with rear final drive 02D/0AV”, page 3
⇒ “2.2 Audi A3 with rear final drive 0BR”, page 5
2.1 Audi A3 with rear final drive 02D/0AV
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive
02D
1)
Part No. 02D.525.010.AA 02D.525.010.AC 02D.525.010.AQ
Code letters FWR HEY HEZ
Manufactured from 07.03 11.04 01.04
to 01.04 12.04 08.04
Allocation Model Audi A3 2004 ▸ Audi A3 2004 ▸ Audi A3 2004 ▸
Engine 2.0 ltr. - 147 kW
2.0 ltr. - 103 kW TDI 2.0 ltr. - 147 kW TFSI
TFSI
Ratio: Z2 : Z
1
Final drive
3.2 ltr. - 184 kW
27 : 17 = 1.588 27 : 17 = 1.588 27 : 17 = 1.588
3.2 ltr. - 184 kW
(rear)
Drive shaft flange ∅ 100 mm 100 mm 100 mm
Capacity in final drive 0.95 litres
Capacity in Haldex coupling 0.85 litres
Oil change capacity in Haldex cou‐
pling
• Change intervals: ⇒ Mainte‐
0.65 litres
nance tables “ELSA”
1)
Rear final drive “02D” is equipped with “Haldex coupling 2”
The following data can be found in the ⇒ Electronic parts catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
Rear final drive
0AV
1)
Part No. 0AV.525.010 0AV.525.010.A 0AV.525.010.B
Code letters HHJ HHK HVY
Manufactured from 09.05 11.04 11.05
to 11.05 11.05 05.07
Allocation Model Audi A3 2004 ▸ Audi A3 2004 ▸ Audi A3 2004 ▸
Ratio: Z2 : Z
1
Engine 2.0 ltr. - 147 kW TFSI 2.0 ltr. - 103 kW TDI 2.0 ltr. - 147 kW TFSI
3.2 ltr. - 184 kW
Final drive
3.2 ltr. - 184 kW
27 : 17 = 1.588 27 : 17 = 1.588 27 : 17 = 1.588
(rear)
Drive shaft flange ∅ 100 mm 100 mm 100 mm
Capacity in final drive 0.95 litres
Capacity in Haldex coupling 0.85 litres
2. Audi A3 2004 ▸ – Code letters, allocation, transmission ratios, capacities 3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Rear final drive
0AV
1)
Part No. 0AV.525.010 0AV.525.010.A 0AV.525.010.B
Code letters HHJ HHK HVY
Oil change capacity in Haldex cou‐
0.65 litres
pling
• Change intervals: ⇒ Mainte‐
nance tables “ELSA”
1)
Rear final drive “0AV” is equipped with “Haldex coupling 2”
The following data can be found in the ⇒ Electronic parts catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
Rear final drive
0AV
1)
Part No. 0AV.525.010.C 0AV.525.010.D 0AV.525.010.E
Code letters HVZ JJN JYP
Manufactured from 11.05 11.06 06.07
to 05.07 01.08 02.08
Allocation Model Audi A3 2004 ▸ Audi A3 2004 ▸ Audi A3 2004 ▸
Ratio: Z2 : Z
1
Engine 2.0 ltr. - 103 kW TDI 2.0 ltr. - 147 kW TFSI
2.0 ltr. - 195 kW TFSI
2.0 ltr. - 125 kW TDI 3.2 ltr. - 184 kW 2.0 ltr. - 125 kW TDI
Final drive
27 : 17 = 1.588 27 : 17 = 1.588 27 : 17 = 1.588
2.0 ltr. - 103 kW TDI
(rear)
Drive shaft flange ∅ 100 mm 100 mm 100 mm
Capacity in final drive 0.95 litres
Capacity in Haldex coupling 0.85 litres
Oil change capacity in Haldex cou‐
0.65 litres
pling
• Change intervals: ⇒ Mainte‐
nance tables “ELSA”
1)
Rear final drive “0AV” is equipped with “Haldex coupling 2”
The following data can be found in the ⇒ Electronic parts catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
Rear final drive
0AV
1)
Part No. 0AV.525.010.K 0AV.525.010.L
Code letters KJS KJT
Manufactured from 09.07 02.08
to 06.08 06.08
Allocation Model Audi A3 2004 ▸ Audi A3 2004 ▸
Engine 2.0 ltr. - 147 kW TFSI
2.0 ltr. - 103 kW TDI
2.0 ltr. - 195 kW TFSI
3.2 ltr. - 184 kW 2.0 ltr. - 125 kW TDI
4 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Rear final drive
0AV
1)
Part No. 0AV.525.010.K 0AV.525.010.L
Code letters KJS KJT
Ratio: Z2 : Z
1
Final
27 : 17 = 1.588 27 : 17 = 1.588
drive
(rear)
Drive shaft flange ∅ 100 mm 100 mm
Capacity in final drive 0.95 litres
Capacity in Haldex coupling 0.85 litres
Oil change capacity in Haldex
0.65 litres
coupling
• Change intervals: ⇒ Main‐
tenance tables “ELSA”
1)
Rear final drive “0AV” is equipped with “Haldex coupling 2”
The following data can be found in the ⇒ Electronic parts catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
2.2 Audi A3 with rear final drive 0BR
Rear final drive
Part No. 0BR.525.010
Code letters KMC
Manufac‐
from 07.08
tured
to
Allocation ModelAudi A3 2004
▸
En‐
gine
1.8 ltr. - 118
kW TFSI
2.0 ltr. - 147
kW TFSI
2.0 ltr. - 188
kW TFSI
2.0 ltr. - 195
kW TFSI
3.2 ltr. - 184
kW
2.0 ltr. - 103
kW TDI
Ratio: Z2 :
Z
1
Fi‐
nal
driv
27 : 17 =
1.588
e
(rear
)
Drive shaft flange∅100 mm
1)
0BR
Capacity in final
drive
Capacity in Hal‐
dex coupling
0.95 litres
0.85 litres
2. Audi A3 2004 ▸ – Code letters, allocation, transmission ratios, capacities 5
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Rear final drive
Part No. 0BR.525.010
Code letters KMC
Oil change ca‐
1)
0BR
0.70 litres
pacity in Haldex
coupling
• Change inter‐
vals: ⇒ Main‐
tenance ta‐
bles “ELSA”
1)
Rear final drive “0BR” is equipped with “Haldex coupling 4”
The following data can be found in the ⇒ Electronic parts
catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
6 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
3 Audi TT 2007▸ – Code letters, allo‐
cation, transmission ratios, capaci‐
ties
⇒ “3.1 Audi TT with rear final drive 02D/0AV”, page 7
⇒ “3.2 Audi TT with rear final drive 0BR”, page 8
⇒ “3.3 Audi TT RS with rear final drive 0BY”, page 9
3.1 Audi TT with rear final drive 02D/0AV
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive
0AV
1)
Part No. 0AV.525.010.B 0AV.525.010.D 0AV.525.010.F
Code letters HVY JJN JUY
Manufactured from 11.05 11.06 03.07
to 05.07 - -
Allocation Model Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
Engine
3.2 ltr. - 184 kW 3.2 ltr. - 184 kW 3.2 ltr. - 184 kW
Ratio: Z2 : Z
1
Final drive
27 : 17 = 1.588 27 : 17 = 1.588 27 : 17 = 1.588
(rear)
Drive shaft flange ∅ 100 mm 100 mm 100 mm
Capacity in final drive 0.95 litres
Capacity in Haldex coupling 0.85 litres
Oil change capacity in Haldex cou‐
pling
0.65 litres
• Change intervals: ⇒ Mainte‐
nance tables “ELSA”
1)
Rear final drive “0AV” is equipped with “Haldex coupling 2”
The following data can be found in the ⇒ Electronic parts catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
Rear final drive
0AV
1)
Part No. 0AV.525.010.H 0AV.525.010.K 0AV.525.010.M
Code letters JZX KJS KJU
Manufactured from 08.06 12.07 12.07
to 11.06 - -
Allocation Model Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
Engine
3.2 ltr. - 184 kW 3.2 ltr. - 184 kW 3.2 ltr. - 184 kW
Ratio: Z2 : Z
1
Final drive
27 : 17 = 1.588 27 : 17 = 1.588 27 : 17 = 1.588
(rear)
Drive shaft flange ∅ 100 mm 100 mm 100 mm
Capacity in final drive 0.95 litres
Capacity in Haldex coupling 0.85 litres
3. Audi TT 2007▸ – Code letters, allocation, transmission ratios, capacities 7
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Rear final drive
0AV
1)
Part No. 0AV.525.010.H 0AV.525.010.K 0AV.525.010.M
Code letters JZX KJS KJU
Oil change capacity in Haldex cou‐
0.65 litres
pling
• Change intervals: ⇒ Mainte‐
nance tables “ELSA”
1)
Rear final drive “0AV” is equipped with “Haldex coupling 2”
The following data can be found in the ⇒ Electronic parts catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
3.2 Audi TT with rear final drive 0BR
Rear final drive
Part No. 0BR.525.010 0BR.
Code letters KMC KMD
Manufac‐
from 01.08 01.08
tured
to
Allocation ModelAudi TT 2007▸Audi TT 2007
En‐
gine
2.0 ltr. - 195
kW TFSI
2.0 ltr. - 199
2.0 ltr. - 195
2.0 ltr. - 199
kW TFSI
Ratio: Z2 :
Z
1
3.2 ltr. - 184kW3.2 ltr. - 184
Fi‐
27 : 17 =
nal
1.588
driv
e
(rear
)
Drive shaft flange∅100 mm 100 mm
1)
0BR
525.010.A
-
▸
kW TFSI
kW TFSI
kW
27 : 17 =
1.588
Capacity in final
0.95 litres
drive
Capacity in Hal‐
0.85 litres
dex coupling
Oil change ca‐
0.70 litres
pacity in Haldex
coupling
• Change inter‐
vals: ⇒ Main‐
tenance ta‐
bles “ELSA”
1)
Rear final drive “0BR” is equipped with “Haldex coupling 4”
8 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Rear final drive
Part No. 0BR.525.010 0BR.
0BR
1)
525.010.A
Code letters KMC KMD
The following data can be found in the ⇒ Electronic parts
catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
3.3 Audi TT RS with rear final drive 0BY
Rear final drive
Part No. 0BY.525.010
Code letters LEK
Manufac‐
from 01.09
tured
to
Allocation ModelAudi TT RS
2007▸
En‐
gine
2.5 ltr. - 250
kW TFSI
Ratio: Z2 :
Z
1
Fi‐
nal
driv
27 : 17 =
1.588
e
(rear
)
Drive shaft flange∅100 mm
1)
0BY
Capacity in final
0.95 litres
drive
Capacity in Hal‐
0.85 litres
dex coupling
Oil change ca‐
0.70 litres
pacity in Haldex
coupling
• Change inter‐
vals: ⇒ Main‐
tenance ta‐
bles “ELSA”
1)
Rear final drive “0BY” is equipped with “Haldex coupling 4”
The following data can be found in the ⇒ Electronic parts
catalogue
♦ Specification of gear oil for rear final drive
♦ Specification of high performance oil for Haldex coupling
♦ Allocation of gearbox
3. Audi TT 2007▸ – Code letters, allocation, transmission ratios, capacities 9
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
4 Transmission layout
♦ Illustrated with 6-speed manual gearbox 02Q, four-wheel drive
Identification
Note
Arrows point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox or direct
shift gearbox
4 - Input shaft
5 - Output shaft for 5th, 6th and
reverse gear
6 - Output shaft for 1st - 4th
gear
7 - Differential
8 - Bevel box
9 - Propshaft
10 - Haldex coupling
11 - Rear final drive
12 - Differential
Ratio
Note
Arrows point in direction of travel.
10 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
W 1 - Front bevel gears
W 2 - Rear bevel gears
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
4. Transmission layout 11
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
5 General repair instructions
Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the final drive. The usual basic
safety precautions also naturally apply when carrying out repair
work.
A number of generally applicable instructions for the various re‐
pair procedures are summarised here under the designation
“Components” ⇒ page 14 . They apply to the work described in
this Manual.
5.1 Gear oil and oil for Haldex coupling
Caution
The final drive and the “Haldex coupling” have separate oil cir‐
cuits.
♦ The Haldex coupling is filled with high-performance oil for
Haldex coupling . For part number, refer to ⇒ Electronic
parts catalogue .
♦ The final drive is filled with “gear oil”. For part number,
refer to ⇒ Electronic parts catalogue .
12 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Location of oil filler plugs and drain plugs
A - Filler plug for high performance oil for Haldex coupling
B - Drain plug for high performance oil for Haldex coupling
1 - Filler plug for gear oil
2 - Drain plug for gear oil
Caution
Different types of high-performance oil for Haldex coupling
♦ The rear final drive units “02D/0AV” and “0BR/0BY” have
different “Haldex couplings” and therefore different types
of oil for the Haldex coupling.
♦ The two different types of oil for the Haldex couplings must
not be interchanged or mixed together.
♦ Part number for high performance oil for Haldex coupling
⇒ Electronic parts catalogue .
♦ Note the distinguishing markings for the different rear final
drive units ⇒ page 1 .
Audi A3 2004 ➤ , Audi TT 2007 ➤
♦ Checking oil level in rear final drive and topping up
⇒ page 123 .
♦ Checking oil level in Haldex coupling and topping up
⇒ page 115 .
♦ Do not use any “additives” in the oil.
♦ Do not re-use oil that has been drained off.
Regulations for the disposal of oil
Drained oil must be disposed of properly.
♦ Improper disposal of used oil endangers the environment.
♦ It must not be mixed with solvents, brake fluid, coolant or sim‐
ilar.
♦ Please observe the information shown on the packaging of the
oil.
5. General repair instructions 13
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
5.2 Components
Guided fault finding, vehicle self-diagnosis and testing system
♦ Before servicing the Haldex coupling, the exact cause of the
failure must be determined as precisely as possible via the
vehicle diagnostic, testing and information system -VAS
5051B- in the modes “Guided Fault Finding”, “vehicle self-di‐
agnosis” and “testing system”.
– Connecting vehicle diagnostic, testing and information system
- VAS 5051B- and selecting functions ⇒ page 53 .
WARNING
To avoid any risk of accident, observe the
⇒ “6 Safety precautions”, page 16 when road-testing the ve‐
hicle and using test equipment.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ "Workshop equipment and special tools" .
Rear final drive
♦ When renewing the rear final drive, check gear oil level and oil
level of the Haldex coupling and top up if necessary:
⇒ page 123 and ⇒ page 115 .
♦ Capacity, Audi A3 ⇒ page 3 .
♦ Capacity, Audi TT ⇒ page 7 .
♦ Specifications ⇒ Electronic parts catalogue .
♦ When installing mounting brackets as well as other waxed
components, the contact surfaces must be cleaned. The con‐
tact surfaces must be free of wax and grease.
O-rings, oil seals and gaskets
♦ Always renew O-rings, seals and gaskets.
♦ Thoroughly clean joint surfaces.
Before installation:
♦ Before installing oil seals, lightly oil outer circumference and
fill space between sealing lips -arrow- with a thin layer of
grease.
♦ The open side of the oil seals faces toward the side with fluid
filling.
After installation:
♦ Check gear oil level in rear final drive ⇒ page 123 .
♦ Check oil level in Haldex coupling and top up as necessary
⇒ page 115 .
Locking elements
14 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
♦ Do not over-stretch circlips.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.
Nuts, bolts
♦ Nuts and bolts for securing covers and housings must be
slackened and tightened in diagonal sequence.
♦ Loosen and tighten particularly sensitive parts in diagonal se‐
quence and in stages, taking care to keep them straight.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and nuts.
♦ For all threaded connections, ensure that (where applicable)
the contact surfaces and the nuts and bolts are not coated with
wax until after assembly is completed.
Bearings
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
♦ Lubricate all bearings in final drive with gear oil when installing.
♦ Always renew the tapered roller bearings on one shaft togeth‐
er as a set and use new bearings from a single manufacturer.
♦ Heat inner races to approx. 100° C before installing.
♦ Do not interchange the outer or inner races of bearings of the
same size (the bearings are paired).
Shims
♦ Measure shims at several points with a micrometer. Tolerance
variations make it possible to obtain the exact shim thickness
required.
♦ Check for burrs and damage.
♦ Install only shims which are in perfect condition.
Audi A3 2004 ➤ , Audi TT 2007 ➤
5.3 Contact corrosion!
Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con‐
ductive materials.
If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ Use only genuine spare parts: these have been fully tested
and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
5. General repair instructions 15
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
6 Safety precautions
⇒ “6.1 Safety precautions for Audi TT and Audi A3 Cabriolet”,
page 16
⇒ “6.2 Safety precautions for Audi A3”, page 17
6.1 Safety precautions for Audi TT and Audi A3 Cabriolet
Observe the following precautions if tests have to be performed
with the engine running.
WARNING
Vehicles with dual clutch gearbox: accidents can be caused if
a gear is inadvertently engaged while the engine is running.
♦ Before working on the vehicle while the engine is running,
shift the selector lever into position “P” and apply the
handbrake.
Danger from toxic fumes!
♦ When the engine is running, the exhaust system must al‐
ways be connected to the exhaust gas extractor.
16 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Observe the following precautions if test equipment has to be
used while road-testing the vehicle:
WARNING
Accidents can be caused if the driver is distracted by test
equipment while road-testing, or if test equipment is not se‐
cured.
Injuries can also be caused if the passenger's airbag is trig‐
gered in a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
TT Coupé:
Always secure testing equipment to the rear seat with a strap
and have them operated from there by a second person.
TT Roadster:
♦ Move the passenger's seat to the rearmost position.
♦ Use only vehicle diagnosis and service information sys‐
tem -VAS 5052- or diagnosis system -VAS 5053- .
♦ Test equipment may only be operated by the passenger;
the tester -1- must be placed flat on the passenger's lap
as illustrated.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Observe the following precautions to avoid possible injury and/or
damage to electrical and electronic components:
♦ Switch off ignition before disconnecting and connecting test
equipment.
Caution
When disconnecting the battery there is a risk of serious dam‐
age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery.
♦ Always switch off the ignition before disconnecting the
battery.
6.2 Safety precautions for Audi A3
Safety precautions for Audi A3 Cabriolet ⇒ page 16
6. Safety precautions 17
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Observe the following precautions to avoid possible injury and/or
damage to the vehicle:
WARNING
Vehicles with dual clutch gearbox: accidents and injury can be
caused if a gear is inadvertently engaged while the engine is
running.
♦ Before working on the vehicle while the engine is running,
shift the selector lever into position “P” and apply the
handbrake.
Danger from toxic fumes!
♦ When the engine is running, the exhaust system must al‐
ways be connected to the exhaust gas extractor.
Observe the following precautions if test equipment has to be
used when road-testing the vehicle.
WARNING
Accidents can be caused if the driver is distracted by test
equipment or if test equipment is not secured.
Injuries can be caused if the passenger's airbag is triggered in
a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Always secure testing equipment to the rear seat with a
strap and have them operated from there by a second
person.
Observe the following precautions to avoid possible injury and/or
irreparable damage to electrical and electronic components:
♦ Switch off ignition before disconnecting and connecting test
equipment.
Caution
When disconnecting the battery there is a risk of serious dam‐
age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Rep. Gr. 27 .
18 Rep. Gr.00 - Technical data
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
39 – Final drive - rear differential
1 Exploded view – propshaft with de‐
tachable centre bearing (up to 05.07)
The propshaft with detachable centre bearing was installed as
follows:
♦ Audi TT up to vehicle identification number 8J-8-011 000
♦ Audi A3 up to and including model year 2007
Special tools and workshop
equipment required
♦ Drive flange installing tool -
VW 391-
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 408A-
♦ Drift sleeve -VW 244B-
Audi A3 2004 ➤ , Audi TT 2007 ➤
1. Exploded view – propshaft with detachable centre bearing (up to 05.07) 19
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
♦ Support sleeve -VW 522-
♦ Tensioner -40-204A-
♦ Hose clip pliers -V.A.G
1275/-
♦ Torque wrench -V.A.G
1331/-
♦ Circlip pliers -VW 161A-
♦ Puller -2 - Kukko 18/0-
♦ Splitter -3 - Kukko 17/1-
♦ Thrust plate -40 - 105-
20 Rep. Gr.39 - Final drive - rear differential
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Two-arm puller -1 Kukko 20/10-
♦ Support plate -T10108/1-
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Note
♦
In order to achieve the quietest possible running, only the
complete propshaft is balanced during manufacture. The bal‐
ancing of the complete propshaft or the individual propshaft
tubes cannot be carried out with workshop equipment. There‐
fore, if the front or rear propshaft tube is damaged, always
renew the complete propshaft.
♦
Do not bend propshaft; only store and transport fully extended.
♦
Before removing, mark the positions of all parts in relation to
each other. Reinstall in the same position to avoid excessive
imbalance, resulting in bearing damage and rumbling noise.
♦
Removing and installing propshaft ⇒ page 27
1. Exploded view – propshaft with detachable centre bearing (up to 05.07) 21
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
1 - Manual gearbox with bevel
box
2 - Bolt
❑ 50 Nm + 90°
❑ Always renew
3 - Flexible coupling with heat
shield
❑ Installation position:
open side of heat shield
points towards gearbox
❑ Removing and installing
⇒ page 27
4 - Bolt
❑ 60 Nm
❑ Allocation ⇒ page 31
5 - Centring sleeve
6 - Propshaft tube (front)
❑ Do not damage centring
sleeve -5- and seal in
centre of flange when
removing and installing
7 - Bolt
❑ 40 Nm
8 - Lock plate
9 - Clip
❑ Tensioning
⇒ page 24
10 - Boot for constant velocity
joint
❑ Drive off with a drift be‐
fore pressing off CV joint
❑ Check for damage
11 - Dished spring
❑ Inner diameter serrated
❑ Installation position: large diameter lies against CV joint
12 - Gasket
❑ Renew; pull off backing and stick onto joint
13 - Constant velocity joint
❑ Pressing off ⇒ page 23
❑ Pressing on ⇒ page 24
❑ Press 25 g G-6.3 grease from each side (in total 50 g) into joint. Regrease joint if necessary when
renewing boot
14 - Circlip
❑ Renew
❑ Remove and install using circlip pliers -VW 161A-
15 - Bolt
❑ 45 Nm
16 - Washer
❑ Always renew
22 Rep. Gr.39 - Final drive - rear differential
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
17 - Flange
❑ Pulling off ⇒ page 24
❑ Pulling on ⇒ page 25
18 - Centre bearing
❑ Pulling off ⇒ page 25
❑ Installation position ⇒ page 25
❑ Driving on ⇒ page 25
19 - Bolt
❑ 25 Nm
❑ Also secures heat shield
20 - Propshaft tube (rear)
❑ Do not damage centring sleeve -5- and seal in centre of flange when removing and installing
❑ Clamp in a vice to loosen and tighten bolt connections ⇒ page 24
21 - Centring sleeve
22 - Bolt
❑ 60 Nm
❑ Allocation ⇒ page 31
23 - Balancing nut
❑ 10 Nm
❑ Not fitted on all propshafts
❑ If the flange bolt ⇒ Item 25 (page 23) was loosened, the balancing nut and the balancing washer
⇒ Item 24 (page 23) must NOT be re-installed.
24 - Balancing washer
❑ Only fitted on balanced final drive units
25 - Bolt
❑ 50 Nm + 90°
❑ Always renew
26 - Flexible coupling with vibration damper
❑ Installation position ⇒ page 26
27 - Rear final drive
❑ Removing and installing ⇒ page 96
Pressing off constant velocity joint
1. Exploded view – propshaft with detachable centre bearing (up to 05.07) 23
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Pressing on constant velocity joint
– Press on carefully.
– Tighten tensioner -V.A.G 40-204A- firmly; propshaft must not
move out of position in tensioner, as this will cause paint dam‐
age.
– If necessary, repair paint damage as follows: remove grease
residue with nitro thinner -L 001 600- . Apply 2-component
acrylic paint -ALN 769 041- with hardener -ALZ 009 001- .
Tightening clip
Refer to ⇒ Electronic parts catalogue for clip required in the event
of a repair.
Clamp rear propshaft tube into a vice using support plate T10108/1- .
– Secure support plate -T10108/1- to flexible coupling of prop‐
shaft tube.
– To do so, fit nuts -B- onto bolts -A- between support plate -
T10108/1- and flexible coupling.
A - Bolt M10 x 70 mm with nut
B - M12 nut
Pulling off flange
24 Rep. Gr.39 - Final drive - rear differential
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Pressing on flange
Pulling off centre bearing
– The rubber guide of the centre bearing must be cut and the
metal cover removed.
A - Splitter 12...75 mm , e.g. -Kukko 17/1-
B - Puller , e.g. -Kukko 18/0-
– Tighten splitter -A- with straight side of jaws behind centre
bearing.
– Then apply two-arm puller -B- to splitter .
– Pull centre bearing off propshaft tube.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Installation position of centre bearing
The longer shoulder -A- points to left -arrow- (as seen in direction
of travel).
Driving on centre bearing
– Drive on centre bearing until limit stop.
1. Exploded view – propshaft with detachable centre bearing (up to 05.07) 25
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A3 2004 ➤ , Audi TT 2007 ➤
Rear final drive 02D, 0AV, 0BR and 0BY - Edition 06.2009
Installation position of flexible coupling with vibration damper
The shoulder on the outer circumference -arrows- must point
away from the propshaft tube.
26 Rep. Gr.39 - Final drive - rear differential
Loading...