Torsen Differential Cover, Removing and Installing

Torsen differential cover, removing and installing, 09L, 6 Spd. A/T AWD

Special tools, testers and auxiliary items required

Drip tray VAG 1306:

^ Safety goggles

Removing
^ Transmission installed

CAUTION: The engine must not run and the vehicle must not be towed without gear oil.

Note:
^ General repair instructions.
^ Read the rules for cleanliness when working on the automatic transmission.





Vehicles with 2.0 ltr. TFSI engine

Note:
^ The flexible line connection (de-coupling element) on the front exhaust line must not be bent more than 100 - otherwise it can be damaged.

- Loosen nuts on front clamp - arrows -.
- Push clamp toward rear of vehicle to disconnect exhaust system.





Vehicles with 4.2 ltr. MPI engine:

Note:
^ To prevent damage, the flexible couplings in the front exhaust lines must not be bent further than 10°.

- Disconnect exhaust system at clamps - arrows -.
- Disengage rear section of exhaust system at rubber mountings and remove.

Note:
- A second technician is required for removing the rear section of the exhaust system.





- Remove heat shield - A - for driveshaft - arrows -.
- Remove bolts at transmission/driveshaft flange.
- Slide driveshaft together toward rear final drive. The constant velocity joints can be moved axially.





- Tie driveshaft to side, onto heat shield - arrow -.





- Place drip tray V.A.G 1306 under transmission.

CAUTION: Wear safety goggles.

- Loosen securing bolts for cover for Torsen differential in sequence - 6 to 1 - and remove; allow gear oil to drain out.

Note:
^ The cover is not equipped with a drain plug, drain gear oil by removing the cover.

CAUTION: Pull the Torsen differential cover backward from the transmission housing slowly and carefully. The Torsen differential may otherwise fall out of the transmission.





- Secure Torsen differential - B - and baffle plate - A - to prevent them from dropping out, or pull them off output shaft toward the rear.





Installing
Installation is performed in reverse sequence. Note the following:

Note:
^ Replace O-ring on cover for transfer gear.

Note the following if the Torsen differential - B - and the baffle plate - A - have been removed:

- Clean baffle plate, lubricate with gear oil and insert in transmission.
^ Installation position: tongue on baffle plate should be positioned on the transmission so that the side lugs are located above opening - B - - arrow -.





- Install Torsen differential - B - onto splines of output shaft (turn slightly at the same time).

Note:
^ Check installation position of tongue on baffle plate - arrow - again.

- Check whether the attached Torsen differential can be turned manually.
- Check whether tongue - arrow - on baffle plate is still located properly.
- Place cover for Torsen differential with shaft installed onto Torsen differential, turn slightly if necessary.





- Tighten bolts of cover for Torsen differential as follows.





- Install driveshaft.
- Install exhaust system free of stress.
- Top off transfer gear oil.

Tightening Torques: