Rear flange shaft seal, replacing

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

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

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

Pressure application device T10136

Removing

Remove self-locking center differential cover → Self-locking center 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 self-locking center 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.

Remove flange shaft.

Fig 4: Prying Out Oil Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

To do so, place e.g. a pry bar - A - beneath to prevent damage to housing.

Installing

Installation is in reverse order, note the following:

Installing shaft seal:

NOTE:

The two-piece Pressure Application Device T10136 is used to install the shaft seal.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place self-locking center differential cover - A - on thrust plate of 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 edge of shaft seal with axle oil.

Fig 6: Shaft Seal Onto Thrust Piece T10136/1

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide new shaft seal onto thrust piece T10136/1.

Installation position: Open side of shaft seal faces cover.

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

NOTE:

The pin of the thrust piece of the Pressure Application Device T10136 serves as a guide from below and also as a stop for thrust piece T10136/1.

Drive in new shaft seal as far as stop without tilting it.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .

Installing rear flange shaft:

Fig 7: 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 self-locking center 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 8: 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.
Remove self-locking center differential cover → Self-locking center differential cover, removing and installing .
Top off gear oil in transfer case after repair → Gear oil in transfer case, transmissions with separate oil systems, filling after repair .