theraudi1

Hello all! Finally got a chance to give an update and a few hints on replacing the front pass side diff output seal. Let me just say that I've never seen a seal "go" like this. I drove to work and everything was fine. Drove out to lunch (2 miles max) and noticed a burning smell when I parked. Looked under the car and noticed the pass side front was dripping. This was a fast drip. Drove it home later that day (about 12 miles) and let it sit in the garage til I changed the seal. When I ended up changing the seal, the front diff took almost a whole liter of fluid! There is no doubt I would have burned this thing out and killed it if I had driven it any further. I took a few pics along the way to show what I did.

First I took off the wheel and undid the axle to the diff with the 6 triple squares. Next remove the inner CV shield. It's held in place with 3 allens. I didn't want to mess with the dreaded upper double pinch bolt, so I undid the lower front inner control arm bolt and pulled it back just a bit. This gave me just enough room to undo and slide over the axle toward the back. When doing this, keep the wheels pointed straight. Also, do not "stress the CV joints by forcing them too far. I also undid the bottom strut bolt, but I don't think it's necessary.
<img src="http://pictureposter.audiworld.com/87587/pb100245.jpg">

Next I used a T-40 torex to remove the flange from the diff
<img src="http://pictureposter.audiworld.com/87587/pb100243.jpg">

The seal is the orange thing in the following pic. I had to use a seal puller to get the thing out. Be VERY careful not to score the inside of diff where the seal sits! You can also see the fill plug to the right of the seal. It was an allen. Sorry, I don't remember what size
<img src="http://pictureposter.audiworld.com/87587/pb100246.jpg">

I used the flange to press the new seal in. Just seat the new seal the best you can by hand and then put the flange in and tighten down the center T-40 bolt. Not too tight!
<img src="http://pictureposter.audiworld.com/87587/pb100247.jpg">

Well, that's about it. Fill the diff according to audipages.com. I would guess that the driver's side is just as easy!

PaulW

Should I post it on audipages?

poly

Very instructive theraudi1. How difficult is to undo the lower front inner control arm bolt?

theraudi1

If you think it'll help fellow A8'ers, sure Paul!!!

theraudi1

I think it was a 19mm bolt at 66ft-lbs torque. Not much. Hell of a lot easier than the upper bolt

Angus Beef

fun job, piece of cake.

Rtrn4Deposit

Very informative - thanks!!!!