Bevel Box Drive Flange Seal

Special tools and workshop equipment required

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

Procedure

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

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Tightening specification, refer to FLANGE SHAFT, SEALS AND BRACKET ON BEVEL BOX OVERVIEW .

-- Remove the bevel gear. Refer to vehicles with 2.0 TFSI engine BEVEL BOX or vehicles with 3.2L MPI engine BEVEL BOX .

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

-- 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 two M10 x 30 bolts -arrows-.

Fig 2: Identifying New Output Flange Hex Nut

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-- Remove the output flange nut.

A -

Socket SW 36

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

-- Remove the output flange from 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 the output shaft and must be removed from it.

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

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

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

-- Remove output shaft seal -A-.

Fig 5: Identifying Output Shaft Seal

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-- 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
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-- Place the tapered bearing inner race -3- into the outer race inside the bevel box.

-- Lightly coat the outer circumference of the new output flange seal -4- with oil.

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

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

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-- Fill the space between the sealing- and dust lip half way with sealing grease; for the correct sealing grease.

-- Pull the output flange inward; 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

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A -

Kukko 20/10 two-arm puller

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

Fig 9: Identifying New Output Flange Hex Nut

Courtesy of AUDI OF AMERICA, LLC

-- Install the bevel box. Refer to vehicles with 2.0 TFSI engine BEVEL BOX or vehicles with 3.2L MPI engine BEVEL BOX ..

-- Add gear oil to the bevel box. Refer to AXLE OIL, DRAINING, OR FILLING AFTER REPAIRS .