Transmission Output Shaft, Removing And Installing

Special tools and workshop equipment required 

• Press Plate:VW402 
• Press Piece - Multiple Use:VW412 
• Press Piece - Press Tube:30-100 
• Puller - Crankshaft/Power Steering Seal:T20143 
• Seal Installer - Output Shaft:T40239 
• Sealing Grease:G 052 128 A1 

Procedure

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

Fig 1: Circlip On Inner Side Of Cover, Removal/Installation

Courtesy of AUDI

-- Carefully remove the transmission output shaft from the center differential housing using a copper mandrel.

-- Pry out the shaft seal -1-.

Fig 2: Prying Out Shaft Seal

Courtesy of AUDI

Installing

Fig 3: Install Shaft Seal Using T40239

Courtesy of AUDI

-- Coat the outer edge of the shaft seal with axle oil.

• Installed position: The open side of the shaft seal faces the housing.

-- Using the :T40239  -1-, install the shaft seal until it stops. Do not bend the seal.

-- Fill the space between the sealing/dust lip halfway with Sealing Grease:G 052 128 A1  .

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

Fig 4: Identifying Tool Set Up For Shaft Installation

Courtesy of AUDI

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

-- Position the housing with the transmission output shaft on the :VW402  under the shop press.

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

-- Install the transmission output shaft.

-- Install the locking ring -arrow- into the groove on the transmission output shaft.

Fig 5: Circlip On Inner Side Of Cover, Removal/Installation

Courtesy of AUDI

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

-- Fill the gear oil in the transfer case. Refer to GEAR OIL, DRAINING AND FILLING .