Differential shaft seal, replacing

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Fig 1: Identifying Special Tools - Differential Shaft Seal, Replacing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Torque wrench V.A.G 1331
Socket T10023
Thrust pad T40107
Assembly lever

Cleaning solution D 009 401 04

Work procedure

The differential shaft seal can be replaced with transmission installed.

Drain ATF → ATF, draining for ATF flushing process .
Remove differential → Differential, removing and installing
Remove right flange shaft → 39 - FINAL DRIVE, DIFFERENTIAL .

NOTE:

In the case of insufficient accessibility in the vehicle, right flange shaft must not be completely removed. In that case, it only needs to be pulled out of transmission housing a little in order to create enough room to remove and install shaft seal.

CAUTION:

In the following procedures, the differential shaft surface must not come in contact with hard objects. Even small scratches or damage to the differential shaft sealing surface cause lack of seal and the transmission must be replaced completely.

Fig 2: Placing Punch On Side Hole Of Pinion Shaft Seal And Punch Small Hole To Install Metal Screw In Shaft Seal

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Place a punch on a side hole of pinion shaft seal and punch a small hole - arrow - to install a metal screw in shaft seal.

Fig 3: Installing Metal Screw With Large Head In Shaft Seal Hole

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Install metal screw with large head in shaft seal hole.

Fig 4: Using Stable Lever With Center Notch To Install Metal Screw

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Use a stable lever - 1 - with center notch - arrow - to install metal screw.
Position lever on metal screw.

CAUTION: Lay an appropriate wood or plastic plate - 2 - between lever and transmission housing to prevent damage.

The housing must not be damaged.

Remove shaft seal.

Fig 5: Cleaning Breather Tube Using Pressurized Air

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Clean breather tube - arrow - using pressurized air and lay a cloth on interior side of breather tube.

Fig 6: Identifying Differential Shaft Sealing Surface

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Clean differential shaft sealing surface with cleaning solution D 009 401 04 and a soft cloth; to do so turn differential shaft.

Selector shaft lever must not be in position "P".

Remove stubborn deposits with the fingernail, do not use tools at all.

CAUTION:

Do not clean the differential shaft mechanically with tools or polishing paste under any circumstances. Even small scratches or damage to the differential shaft sealing surface cause lack of seal and the transmission must be replaced completely.

Coat outside circumference of shaft seal with ATF.
Check assembly aid T40107/2 for cracks or burrs. Do not use a damaged assembly aid.

Fig 7: Placing Assembly Aid T40107/2 On Pressure Sleeve T40107/1 And Sliding Shaft Seal Onto Pressure Sleeve

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Place assembly aid T40107/2 on pressure sleeve T40107/1 and slide shaft seal - 1 - onto pressure sleeve.

Closed side of shaft seal points towards tool.

Remove assembly aid T40107/2.
Connect pressure sleeve T40107/1 with shaft seal - 1 - to differential shaft.

Fig 8: Bringing Pressure Sleeve T40107/1 Into Correct Position

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Place selector shaft lever in "P" position (all the way back).
Rotate nuts on spindle T40107/3 all the way back.
Rotate spindle T40107/3 to stop with open-end wrench.

NOTE:

This installs spindle securely on differential shaft.

Bring pressure sleeve T40107/1 into correct position.

Tabs - arrows - pressure sleeve circumference must engage in notches on transmission housing.

Fig 9: Pressing Shaft Seal Into Transmission Housing With Pressure Sleeve

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Press shaft seal into transmission housing with pressure sleeve and tighten nut to 17 Nm using Torque wrench V.A.G 1331 and Socket T10023.

Shaft seal must settle for 2 minutes.

After waiting 2 minutes, remove nut and remove pressure sleeve in driving direction.

Fig 10: Checking Whether Shaft Seal Lip Visible From Outside Lies On Cylindrical Differential Shaft Sealing Surface And Not On Chamfer

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Check whether shaft seal lip visible from outside lies on cylindrical differential shaft sealing surface and not on chamfer - arrow - ; press shaft seal on, if necessary
Install right flange shaft → 39 - FINAL DRIVE, DIFFERENTIAL .
Install differential housing and front final drive cover → Differential, removing and installing .

With transmission removed:

NOTE:

To check for leaks, transmission must be reinstalled in vehicle so that a road test can be performed.
Transmission, removing and installing → 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

All:

Fill with ATF → ATF, filling for ATF flushing process .

Fig 11: Performing An Extended Test Drive And Finally Checking For Leaks On Bleeder Hole On Front Final Drive Cover

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Perform an extended test drive and finally check for leaks on bleeder hole - arrow A - on front final drive cover.

NOTE:

The bleeder hole is covered with a protective plate in certain transmissions.
On new transmissions, the bleeder hole is placed to the side so a leak is only visible at side of front final driver cover.
If oil escapes at the bleeder hole, repair must be repeated.