Transmission Output Shaft With Splines, Transmission Output Shaft Ball Bearing With Spines

Special tools and workshop equipment required 

• Thrust Plate VW 401
• Thrust Plate VW 402
• Thrust Disc VW 412
• Tube 60 mm Dia. VW 415 A
• Press Tube 30 - 100
• Press Tube 2040
• Oil Seal Installing Tool T40238

Procedure 

Fig 1: Identifying Circlip

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-- Remove the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL, BOLTED DRIVESHAFT  or CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL, ATTACHED DRIVESHAFT .

-- Remove the circlip -arrow A-.

-- Remove the locking ring -arrow B- as if the ball bearing is also being removed.

Transmission Output Shaft with Splines without Vibration Damper 

Fig 2: Identifying Dust Ring

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-- Pry off the dust ring -1-.

-- Position the center differential housing so that the transmission output shaft with splines does not touch the VW 401 and VW 402 and remove the transmission output shaft with splines.

Fig 3: Pressing Out Flange Shaft

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Transmission Output Shaft with Splines and Vibration Damper 

-- Position the center differential housing so that the vibration damper does not touch the VW 401 and VW 402 and remove the transmission output shaft with splines.

All 

Fig 4: Prying Out Shaft Seal -1-

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-- Pry out the shaft seal -1-.

-- Remove the transmission output shaft ball bearing with splines, if necessary.

Fig 5: Flange Shaft Ball Bearing, Removal

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-- Install the transmission output shaft ball bearing.

Fig 6: Flange Shaft Ball Bearing, Installation

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• The shoulder on the VW 415 A -arrow- faces the VW 412.

-- Coat the seal on the outer circumference lightly with oil and then install it all the way in using T40238.

Fig 7: Coating Seal On Outer Circumference Lightly With Oil And Then Install It All Way In Using T40238

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• Installed position: Open side of the shaft seal faces transmission.

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

-- Install the transmission output shaft into the center differential housing as follows:

Fig 8: Installing Flange Shaft

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-- Attach the vibration damper (if equipped) to the center differential housing. Tightening specification, refer to CENTER DIFFERENTIAL HOUSING OVERVIEW, BOLTED DRIVESHAFT  or CENTER DIFFERENTIAL HOUSING OVERVIEW, ATTACHED DRIVESHAFT .

-- Install the transmission output shaft with splines into the center differential housing from underneath.

-- Position the housing and transmission output shaft on the VW 402 under the shop press.

-- Mount the 30 - 100 on the ball bearing inner race.

-- Install the transmission output shaft.

-- Mount the new locking ring -arrow A- for the transmission output shaft with splines and -arrow B- for the ball bearing.

Fig 9: Identifying Circlip

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Transmission Output Shaft with Splines without Vibration Damper 

Fig 10: Identifying Dust Ring

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-- Install a new dust ring -1-.

All 

-- Install the center differential housing. Refer to CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL, BOLTED DRIVESHAFT  or CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL, ATTACHED DRIVESHAFT .