Output Flange Seal, Replacing

Special tools and workshop equipment required

Press Plate: VW401
Press Plate: VW402
Press Piece - Rod: VW407
Press Piece - Multiple Use: VW412
Press Piece - Bushing - 50 mm Diameter: VW454
Press Piece - Multiple Use: VW455
Support Channels: VW457
Press Piece - Reverse Gear Syncro: 3296
Gearbox Support: T10108 with Gearbox Support Stop Plate: T10108/1
Puller - Taper Roller Bearing: VAG1582
Puller - Taper Roller Bearing - Adapter 13: VAG1582/13
Torque Wrench: VAG1601
Seal Installer - Crankshaft: VW204 B
Dial Gauge Holder: VW387
Press Piece - Multiple Use: 40-105
Socket 34 mm: T50019
Dial Gauge - 0-10 mm: VAS6080
Grease. Refer to the Parts Information.
M10 x 30 bolt (quantity: 2)
M8 x 25 bolt (quantity: 1)
M12 x 10 nut (quantity: 4)

Procedure

NOTE:

A tapered roller bearing inner race is installed on the bevel box output shaft.

This is removed later in the procedure.

Do not replace the tapered roller bearing for the output flange bevel box and the shim!

-- Remove the bevel gear. Refer to BEVEL BOX, REMOVING .

-- Mount the bevel gear on the hole marked with the number "4" -arrow- in the : T10108 . To do this place the M12 x 10 nut -A- between the bevel box and the holding fixture.

Fig 1: Identifying Bevel Box Set On Hole Designated With Number 4 In Gearbox Support T10108

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-- Align the bevel box with the remaining three holes and secure it with the nuts -A- inserted between.

-- Drain the gear oil from the bevel box. Refer to GEAR OIL, DRAINING AND FILLING .

-- Turn the points -arrows- on the twelve point nut -A- back into the recesses on the output flange -B-.

Fig 2: Securing Twelve-Point Nut -A-

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-- Lock the bevel box output shaft with : T10108/1 , install the two M10 x 30 bolts -arrows-.

Fig 3: Identifying New Output Flange Hex Nut

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A - : T50019

-- Remove the drive flange nut.

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

Fig 4: Removing Bolts For Pinion Housing

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-- Remove bolts -arrows- for the pinion housing -A-.

-- Insert a suitable flat head screwdriver -B- into the 3 recesses -arrows- on the pinion housing -A- and carefully pry out the pinion housing and shaft bevel gear.

Fig 5: Insert Suitable Flathead Screwdriver

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-- Place the drive flange -A- evenly on the : VW457 -arrows-.

Fig 6: Shaft Bevel Gear

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-- Remove shaft bevel gear from output shaft -A-.

Secure the shaft bevel gear and tapered roller bearing inner race from falling.

-- Remove output flange -A- from the pinion housing.

Fig 7: Output Flange And Pinion Housing

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NOTE:

The seal -arrow- is found on the output flange.

Fig 8: Identifying Output Flange Seal -Arrow-, Removal And Installation

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The tapered roller bearing inner race must be removed from the drive flange to remove the seals.

Fig 9: Identifying Tapered Roller Bearing Puller V. A. G 1582 And Adapter
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CAUTION:

There is a risk of damaging the tapered roller bearing inner race.

Remove the tapered roller bearing inner race using the : VAG1582/13 .
Replace the bevel box if the inner race for tapered roller bearing is damaged.

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

-- Remove the inner race for tapered roller bearing from output flange with the Tapered Roller Bearing Puller.

-- Remove the output flange seal.

-- Place the old inner race for tapered roller bearing -1- into the pinion housing.

Fig 10: Identifying Inner Race/Tapered Roller Bearing -1- And Output Flange Sealing Ring -2-

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-- Lightly lubricate the outer circumference of the new output flange sealing ring -2-.

-- Install the seal so that it is flush.

Fig 11: Install New Seal

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The larger diameter of the : VW204B points to the seal.

-- Fill the space between the sealing- and dust lip half way with sealing grease. For the correct sealing grease refer to the Parts Information.

-- Install the inner race for tapered roller bearing. Refer to OUTPUT FLANGE SEAL, REPLACING - Place the old inner race for tapered roller bearing -1- into the pinion housing. all the way onto the output flange.

Fig 12: Identifying Inner Race/Tapered Roller Bearing

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The larger diameter of the : VW454 points to the output flange.
Install the inner race for tapered roller bearing until stop. Do not apply any greater pressure to the tapered roller bearing.

-- Fit the shim -2-, the inner race for tapered roller bearing -3- and the pinion housing -4- onto the shaft bevel gear -1-.

Fig 13: Inner Race/Tapered Roller Bearing And Pinion Housing

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Install the old adjustment shim -2-. This will maintain the bearing pre-load on the shaft bevel gears inside the pinion housing.

-- Carefully press the pinion housing with the output flange until stop on the shaft bevel gear.

Fig 14: Identifying Thrust Disc VW 412, Thrust Tube VW 454, Thrust Tube VW 455 And Thrust Plate VW 401

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The shoulder -arrow- of the : VW455 points to the shaft bevel gear.
Turn pinion housing during pressing procedure.

-- Align the old adjustment shim -3- to the pinion housing -2-.

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The pinion housing -2- and shim -3- only fit one way.

-- Lubricate the new O-ring -1- with axle oil and slide it onto the pinion housing -2-.

-- Place the pinion housing -2- in the axle drive housing -4-.

NOTE:

The splines from the shift and head bevel gear must come in contact.

Align the openings for the pinion housing bolts to the axle drive housing.

-- Tighten the bolts -1- alternating in small steps, all the while turning the output flange -2- back and forth gently in directions of -arrow-.

Fig 15: Tightening Bolts

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-- Tighten the bolts -arrows- for the pinion housing -A- diagonally.

Fig 16: Removing Bolts For Pinion Housing

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-- Tighten new output flange twelve-point nut.

Fig 17: Identifying New Output Flange Hex Nut

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A - : T50019

-- Secure twelve-point nut -A-.

Fig 18: Securing Twelve-Point Nut -A-

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-- Nut is offset by 120°, cover in the beading -B- on the output shaft with peen -arrows-.

Measure the Radial Run-Out on the Output Flange/Shaft Bevel Gear

Fig 19: Measure the Radial Run-Out on the Output Flange/Shaft Bevel Gear

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NOTE:

Check the radial run-out on the shaft bevel gear centering pin after tightening the output flange nut.

-- Fasten the measuring tools to bevel box with the M8 x 25 bolt -a-.

-- Position the : VAS6080A on the shaft bevel gear centering pin -B- and set the 1 mm pre-tension to "0".

-- Turn the output flange one complete rotation -arrow-.

-- Read the measured value on the gauge.

Radial run-out: maximum 0.05 mm.

-- Install the bevel box. Refer to BEVEL BOX, INSTALLING .

-- Check the gear oil level. Refer to GEAR OIL, CHECKING LEVEL .

Tightening Specifications:

Refer to OVERVIEW - BEVEL BOX .