Flange/Driveshaft And Seal With Rear Final Drive Removed

Special tools and workshop equipment required

PullerVW 391
Slide Hammer - Complete SetVW 771
Pulling hookVW 771/37
Thrust PieceT40112
Retainer3028
Seal Driver-Frt Wheel Bearing 3143
AdapterT10235
Friction MeterVAS 6222
Inductive Heat UnitVAS 6414
Sealing GreaseG 052 128 A1
Locking FluidAMV 185 101 A1
Three M8 x 25 bolts
2 bolts M10 x 40

-- Follow the General Repair Instructions. Refer to COMPONENT DESCRIPTION .

-- Remove rear final drive. Refer to REAR FINAL DRIVE .

-- Attach the rear final drive to the holding fixtureVW 540 using M10 x 40 bolts -arrows-.

Fig 1: Attach Rear Final Drive To Holding Fixture

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-- Measure the friction torque before loosening the pinion nuts.

Fig 2: Measuring Friction Torque

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-- Write down this value.

CAUTION:

The measured value must be adjusted again after replacing the shaft seal.

-- Attach the 3028 to the flange/driveshaft with the bolts -A-.

Fig 3: Attach 3028 To Flange/Driveshaft With Bolts -A-

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-- Attach the T10235 in the threaded hole under the flange/driveshaft.

-- Loosen the pinion nut. The 3028 will be supported by the T10235 -arrow-.

-A- three M8 x 25 bolts

-B- 32 mm socket

-C- bar

-- Install the VW 391 with two M8 x 25 bolts -arrows-.

Fig 4: Pulling Off Drive Shaft Flange Using Puller VW 391

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-- Remove the flange/driveshaft.

-- Remove the shaft seal.

Fig 5: Removing Shaft Seal

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-- Clean the thread on the pinion.

-- Coat the outer circumference of the shaft seal with gear oil.

Fig 6: Installing New Shaft Seal All Way Without Tilting It

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-- Fill the space between the sealing and dust lips halfway with sealing greaseG 052 128 A1.

-- Install the new shaft seal all the way without tilting it.

-- Warm the flange/driveshaft to approximately 80 °C (176 °F) with an VAS 6414.

Fig 7: Driving On Flange/Driveshaft Far Enough Until Circlip Can Be Installed

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-- Install the new flange/driveshaft.

-- Coat the thread on the new nut with locking fluidAMV 185 101 A1.

-- Attach the 3028 to the flange/driveshaft with the bolts -A-.

Fig 8: Attach 3028 To Flange/Driveshaft With Bolts -A-

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-- The 3028 must be supported by the housing brace -arrow- when tightening the pinion nut.

-A- three M8 x 25 bolts

-B- 32 mm socket

-C- bar

CAUTION:

Slowly increase the torque and read the friction torque several times. Do not exceed the friction torque measured before removal otherwise the rear final drive will have to be replaced.

-- Tighten the new pinion nut just far enough until the friction torque, measured prior to removal, is reached.

Fig 9: Measuring Friction Torque

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-- Install rear final drive. Refer to REAR FINAL DRIVE .

-- Check the gear oil in the rear final drive. Refer to REAR FINAL DRIVE GEAR OIL, CHECKING .