Rear flange shaft oil seal, replacing

WARNING: This page is about a different variant/trim than selected.

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools - Rear Flange Shaft Oil Seal, Replacing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thrust plate VW 401
Thrust plate VW 402
Thrust pad VW 447 i
Punch VW 409

Pressure application device T10136

Removing

Remove Torsen differential cover → Torsen differential cover, removing and installing .

Fig 2: Removing/Installing Circlip On Inner Side Of Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove circlip - arrow - on inner side of cover.

NOTE:

The circlip secures the flange shaft to the bearing in the cover.

Fig 3: Press Flange Shaft Out Of Torsen Differential Cover Using Punch VW 409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press flange shaft out of Torsen differential cover using punch VW 409.

Place cover on thrust plates VW 401 and VW 402.

NOTE:

Hold flange shaft - A - with one hand to prevent it falling.

Fig 4: Prying Out Oil Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove oil seal.

NOTE:

Place e.g. a pry bar - A - underneath to prevent damage to the housing when removing the seal.

Installing

Fig 5: Placing Torsen Differential Cover On Pressure Application Device T10136

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install in reverse order of removal, note the following:

Installing seal:

NOTE:

For installing the seal, the two-piece pressure application device T10136 is used.

Fig 6: Placing Torsen Differential Cover On Pressure Application Device T10136

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place Torsen differential cover - A - on pressure application device T10136.

NOTE:

The pin in the middle of the tool is centered and faces upward into the cover. It serves as a guide and stop for thrust piece T10136/1.

Coat outer circumference of seal with gear oil.
Push new seal onto thrust piece T10136/1.

Installation position: Open side of seal faces cover.

Fig 7: Shaft Seal Onto Thrust Piece T10136/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert thrust piece T10136/1 with seal into cover from above.

NOTE:

The pin of the pressure application device T10136 serves as a guide from below and also as a stop for thrust piece T10136/1.

Drive new seal in as far as stop; be sure not to distort seal.
Half fill space between sealing lip and dust lip with sealing grease G 052 128 A1 .

Installing rear flange shaft:

Fig 8: Pressing Flange Shaft Into Self-Locking Center/Torsen Differential Cover Using Punch VW 409 And Thrust Pad VW 447i

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press flange shaft into Torsen differential cover using punch VW 409 and thrust pad VW 447 i.

Place cover on thrust plates VW 401 and VW 402.

NOTE:

Only press in flange shaft as far as necessary to install circlip.

Fig 9: Removing/Installing Circlip On Inner Side Of Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install circlip - arrow - in groove of flange shaft on inner side of cover.
Install Torsen differential cover → Torsen differential cover, removing and installing .
Top off gear oil in transfer case after repair → Transfer case gear oil, topping off after repairs .