Rear Flange Shaft, Seal And Ball Bearing, Removing And Installing

Special tools and workshop equipment required 

• Press Plate VW401
• Press Plate VW402
• Press Piece - Multiple Use VW412
• Press Piece - 60mm VW415A
• Press Piece - Press Tube 30-100
• Press Piece - Front Control Arm 2040
• Seal Installer - Cardan Flange T40165
• Plate T40285 for vehicles with torsional vibration damper or without vibration damper
• Grease.

Procedure 

Fig 1: Identifying Circlip

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

-- Remove the circlip -arrow-.

Transmission with Bolted Vibration Damper 

-- Remove the flange shaft by positioning the center differential housing so the flange shaft does not touch the Press Plate VW401 and Press Plate VW402.

Fig 2: Pressing Out Flange Shaft

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Transmission with Torsional Vibration Damper or without Vibration Damper 

-- Remove the flange shaft by allowing the housing for the center differential to rest on the Plate T40285.

Fig 3: Resting Center Differential On Plate T40285

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All Transmissions 

-- Pry out the shaft seal -1-.

Fig 4: Prying Out Shaft Seal

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-- Remove the flange shaft ball bearing and spacer sleeve if necessary.

Fig 5: Flange Shaft Ball Bearing, Removal

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-- Installing the flange shaft ball bearing.

Fig 6: Flange Shaft Ball Bearing, Installation

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• The shoulder on the Press Piece - 60mm VW415A -arrow- faces the Press Piece - Multiple Use VW412.

-- The press in the spacer sleeve -item  4 using the Press Piece - 60mm VW415A. (See OVERVIEW - CENTER DIFFERENTIAL HOUSING, BOLTED DRIVESHAFT - Figure).

-- Lightly oil the outer circumference on the shaft seal and then install it all the way using the Seal Installer - Cardan Flange T40165.

Fig 7: Cardan Flange T40165 Seal Installer

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

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

-- Install the flange shaft.

Fig 8: Identifying Tool Set Up/Assembly

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-- Install the flange shaft into the center differential housing from underneath.

-- Position the housing and flange shaft on the Press Plate VW402 under the shop press.

-- Press in the bearing inner race using the Press Piece - Press Tube 30-100 on the flange shaft.

-- Install a new circlip -arrow- on the flange shaft.

Fig 9: Identifying Circlip

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