Output Shaft Seal, Replacing

Special tools and workshop equipment required 

• Puller - Unit InjectorT10055
• Seal Installer - Output Shaft Oil SealT10180
• Seal Installer - Output Shaft Oil SealT10186
• Sheet metal screw

Procedure

Fig 1: Identifying Transfer Case Bolts -Arrows 1 And 2-

Courtesy of AUDI OF AMERICA, LLC

-- Remove transfer case. Refer to TRANSFER CASE, REMOVING AND INSTALLING .

-- To remove seal, install a sheet metal screw of approximately 4 mm diameter in shaft seal -arrow-.

Fig 2: Identifying Output Shaft Seal, Removal

Courtesy of AUDI OF AMERICA, LLC

• Install sheet metal screw in so that it jams between seal and metal ring.
• Be careful not to install the screw too deep otherwise the bearing underneath will get damaged.

-- Remove the seal with the Puller - Unit InjectorT10055 and Puller - Unit Injector - Adapter 2T10055/2.

-- New shaft seal must be coated with ATF, especially at sealing lips.

Fig 3: Identifying Oil Seal Sealing Lips

Courtesy of AUDI OF AMERICA, LLC

-- First position Seal Installer - Output Shaft Oil SealT10186 onto input shaft so that shaft seal is not damaged when installed.

Fig 4: Identifying Output Shaft Seal, Installation

Courtesy of AUDI OF AMERICA, LLC

-- Then, drive in new seal up stop using Seal Installer - Output Shaft Oil SealT10180. Do not tilt shaft seal when doing so.

-- Install transfer case. Refer to TRANSFER CASE, REMOVING AND INSTALLING .

-- Refer to ATF LEVEL, CHECKING AND FILLING .