Output Flange Seal, Replacing: Notes

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Special tools and workshop equipment required

Press Plate :VW401
Press Plate :VW402
Press Piece - Rod :VW407
Press Piece - Multiple Use :VW412
Press Piece - Multiple Use :VW454
Press Piece - Multiple Use :VW455
Support Channels :VW457
Press Piece - Reverse Gear Syncro :3296
Gearbox Support :T10108 with Counter Holder :T10108/1
Puller - Taper Roller Bearing :VAG1582
Puller - Taper Roller Bearing - Adapter 13 :VAG1582/13
Torque Wrench 1601 :VAG1601
Seal Installer - Crankshaft :VW204B
Dial Gauge Holder :VW387
Press Piece - Multiple Use :40-105
Dial Indicator :VAS6080A
Socket AF 34mm :T50019
Sealing Grease. Refer to the Parts information.
M10 x 30 bolt (quantity: 2)
M8 x 25 bolt (quantity: 1)
M12 x 10 nut (quantity: 4)

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

Mandatory Replacement Parts

Bolts - Drive Axle
Nut - 12-Point
O-ring - Pinion Housing

A tapered roller bearing inner race is pressed onto the bevel box output flange.
This is removed later in the procedure.
Do not replace the tapered roller bearing for the bevel box output flange and the shims.

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

-- Place the bevel box on the hole -arrow- marked with the number "4" in the :T10108 . Place the M12 x 10 nut -A- between the bevel box and the transmission holder to do so.

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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 peenings -arrows- on the twelve point nut -A- back into the output flange depressions -B-.

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-- Lock the bevel box output flange using the :T10108/1 by installing the two M10 x 30 bolts -arrows-.

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A - :T50019

-- Remove the output flange nut.

-- Pivot the bevel box so that the output flange faces upward.

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

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-- Position a suitable flat-head screwdriver -B- into the three recesses -arrows- on the pinion housing -A- and carefully pry out the pinion housing together with the shaft bevel gear.

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-- Place the output flange -A- evenly onto the :VW457 -arrows-.

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

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

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

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

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The tapered bearing inner race must be removed from the output flange to remove the seal.

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CAUTION:

- Remove the tapered bearing inner race using the Puller - Taper Roller Bearing - Adapter 13:VAG1582/13 .

- Replace the bevel box if the tapered bearing inner race is damaged.

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

-- Remove the tapered bearing inner race from the output flange using the :VAG1582 .

-- Remove the output flange seal.

-- Insert the old tapered bearing inner race -1- into the pinion housing.

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-- Lightly lubricate the outer diameter of the new output flange seal -2-.

-- Install the seal so that it is flush.

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

-- Fill the space between the sealing/dust lip halfway with sealing grease. Refer to the Parts information for the correct sealing grease.

-- Install the tapered bearing inner race. Refer to OUTPUT FLANGE SEAL, REPLACING all the way onto the output flange.

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

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

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Re-install the old shim -2-. This ensures the bearing pre-load of the shaft bevel gear in the pinion housing.

-- Carefully press the pinion housing with the output flange all the way onto the shaft bevel gear.

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

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

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

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

-- Insert the pinion housing -2- into the axle drive housing -4-.

The splines on the shaft 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- in small steps, alternating from side to side. While doing so, turn the output flange -2- back and forth slightly in direction of -arrows-.

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-- Tighten the bolts -arrows- for the pinion housing -A- in a diagonal sequence.

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-- Tighten the new output flange twelve-point nut.

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A - :T50019

-- Secure the twelve-point nut -A-.

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-- With the nut offset by 120°, move it into the output flange depressions -B- -arrows-.

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

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

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

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

-- Read the measured value on the dial 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 .