Torsen Differential Cover, Removing and Installing

Torsen differential cover, removing and installing - 09L, 6 Speed AWD A/T

Special tools, testers and auxiliary items required





^ Drip tray V.A.G 1306
^ Safety goggles

Removing
^ Transmission installed

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

Note:
^ Refer to 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 10° - 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.

Tightening Sequence:

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

Tightening Torques: