Transmission Output Shaft With Splines, 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 - Press Tube 30-100
• Press Piece - Front Control Arm 2040
• Seal Installer - Output Shaft T40238
• Grease.

Procedure 

Fig 1: Identifying Circlip And Lockring

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-- Remove the center differential housing, refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING .

-- Remove the circlip -arrow A-.

-- Remove the locking ring -arrow B- as well 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 thrust plates Press Plate VW401 and Press Plate VW402 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 thrust plates Press Plate VW401 and Press Plate VW402 and remove the transmission output shaft with splines.

All:

Fig 4: Prying Out Shaft Seal

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-- Pry out the shaft seal -1-.

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

Fig 5: Identifying Tool Set Up/Assembly

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-- Install the transmission output shaft ball bearing.

Fig 6: Identifying Tool Set Up/Assembly

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

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

Fig 7: Installing Shaft Seal

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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 transmission output shaft into the center differential housing as follows:

Fig 8: Identifying Tool Set Up/Assembly

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

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

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

-- Mount the Press Plate 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 And Lockring

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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, REMOVING AND INSTALLING .