Bevel Box Drive Flange Seal

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Holding Fixture VW 313
Tube 42 mm Dia. VW 516
Thrust Piece 40-105
Thrust Piece T10049
Transmission Holder T10108
Stop Plate T10108/1
Tapered Roller Bearing Puller V.A.G 1582
Attachment V.A.G 1582/6A
Torque Wrench V.A.G 1601
Slide Hammer-Complete Set VW 771
Pulling Hook VW 771/31
Oil Collecting and Extracting Device V.A.G 1782
M10 x 30 bolt (quantity 2)
M12 x 10 nut (quantity 4)
Kukko 20/10 two-arm puller
Kukko 45/2 three arm puller

Procedure

Tightening specification, refer to FLANGE SHAFT AND SEALS ON BEVEL BOX ASSEMBLY OVERVIEW .
The bevel box is removed. Refer to BEVEL BOX, REMOVING .

-- Place the bevel box on the hole -arrow- marked with the number 4 in the T10108 while laying the M12 x 10 nut -A- between the bevel box and the transmission holder.

Fig 1: Identifying Bevel Box Set On Hole Designated With Number In Transmission Holder T10108

Courtesy of AUDI OF AMERICA, LLC

-- Then align the bevel box with the remaining 3 holes and secure it with the nut -A-.

-- Place the V.A.G 1782 underneath.

-- Drain the axle oil from the bevel box.

-- Bevel box output shaft with T10108/1, install the 2 M10 x 30 bolts -arrows-.

Fig 2: Identifying New Output Flange Hex Nut

Courtesy of AUDI OF AMERICA, LLC

-- Remove the output flange nut.

A - Wrench socket 36 mm ³ /₄ " drive

-- Pivot bevel box so that output shaft faces upward.

-- Remove the output flange form the bevel box shaft bevel gear.

Fig 3: Identifying Removal Of Output Shaft From Bevel Box Shaft Bevel Gear

Courtesy of AUDI OF AMERICA, LLC

A - Kukko 45/2 three arm puller

NOTE:

When removing output shaft, inner race/tapered roller bearing remains on output shaft and must be removed from it.

-- Place the 40 - 105 on the output flange.

-- Remove the inner race of the tapered roller bearing from the output flange using V.A.G 1582 and V.A.G 1582/6A.

Fig 4: Identifying Inner Race/Tapered Roller Bearing, Output Flange And Tapered Roller Bearing Puller

Courtesy of AUDI OF AMERICA, LLC

-- Remove output shaft seal -A-.

Fig 5: Identifying Output Shaft Seal

Courtesy of AUDI OF AMERICA, LLC

-- Clean any remaining locking fluid from the thread on the shaft bevel gear.

Previous shim -2- for shaft beveled gear preload -1- must be installed.

Fig 6: Identifying Shaft Beveled Gear Preload Shim
Courtesy of AUDI OF AMERICA, LLC

-- Install the taper roller bearing inner race -3- into the outer ring in the bevel box.

-- Lightly apply oil to the outer diameter of the new seal -4- for the output flange.

-- Drive in shaft seal as far as stop with T10049.

Fig 7: Driving In New Sealing Ring To Stop Using Thrust Piece T10049

Courtesy of AUDI OF AMERICA, LLC

-- Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

-- Pull the output flange in; when doing this mount the pulling hooks at the bottom of the drive pinion housing.

Fig 8: Identifying Pulling In Output Flange With Two Arm Puller

Courtesy of AUDI OF AMERICA, LLC

A - Two-arm puller Kukko 20/10

-- Coat the new nut for the output flange with locking fluid and then tighten; locking fluid.

Fig 9: Identifying New Output Flange Hex Nut

Courtesy of AUDI OF AMERICA, LLC

-- Replenish axle oil after installation of the bevel box. Refer to GEAR OIL IN BEVEL BOX, FILLING .