Output Flange, Removing And Installing, 0FV

Characteristics of the bevel box. Refer to BEVEL BOX IDENTIFICATION .

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Special tools and workshop equipment required 

• Press Piece - Multiple Use:VW 412 
• Press Piece - Multiple Use:VW 454 
• Press Piece - Multiple Use:VW 455 
• Press Plate:VW 401 
• Two M8 x 30 mm stud bolts or Guide Pins - M8:T10273 
• Removal Device Pin 2:VW 460/2 

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Special tools and workshop equipment required 

• Press Piece - Multiple Use:40-105 
• Seal Installer - Flange Shaft:T10049 
• Gearbox Support:T10108 
• Gearbox Support:T10108/1 
• Puller - Taper Roller Bearing:V.A.G 1582 
• Puller - Taper Roller Bearing - Adapter 13:V.A.G 1582/13 

Special tools and workshop equipment required 

• Dial Indicator Holder:VW 387 

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• Torque Wrench 1601:V.A.G 1601 

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• Three-Arm Puller (Kukko 45/2):VAS 251 205 

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• Dial Indicator:VAS 6080A 

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• Sealing Grease. Refer to the Parts Information.
• Locking fluid. Refer to the Parts Information.
• M10 x 30 bolts (quantity: 2)
• M12 x 10 nuts (quantity: 4)

Procedure

• Pay attention to the different versions of the bevel box. Refer to BEVEL BOX IDENTIFICATION .
• A inner race/tapered roller bearing 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.
• Tightening specifications. Refer to OVERVIEW - BEVEL BOX COMPONENTS, 0FV .

Remove the seal for the output flange

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

-- Place the bevel box on the hole -arrow- marked with "4" in the Gearbox Support:T10108  by placing M12 x 10 nuts -item A- between the bevel box and the transmission holder.

-- Align the bevel box with the remaining three holes and secure it with the nut -A-.

-- Drain the gear oil from the bevel box. Refer to GEAR OIL, DRAINING AND FILLING .

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

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-- Remove the output flange nut.

A -  36 mm Socket for ³ /₄ Drive

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

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

A -  Three-Arm Puller (Kukko 45/2):VAS 251 205 

When removing the output flange the tapered bearing inner race and the seal -arrow- remain on the output flange.

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Remove the seal as follows:

• When removing the output flange seal, the inner race/tapered roller bearing must also be removed.

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-- Place the Press Piece - Multiple Use:40-105  on the output flange.

-- Remove the tapered roller bearing inner race from the output flange using the Taper Roller Bearing Extractor:V.A.G 1582A  and Puller - Taper Roller Bearing - Adapter 13:V.A.G 1582/13  .

-- Remove the output flange seal.

Install the output flange seal

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• First remove the pinion housing -1- along with the shaft bevel gear -2- in order to install the seal.

-- Remove the bolts for the pinion housing -1- ; and carefully remove the pinion housing diagonally off the protruding edges.

-- Remove the pinion housing and the shaft bevel gear -2-.

-- Clean the thread on the shaft bevel gear.

• If the shim -3- was also removed when removing the output flange, it must be reinstalled in the pinion housing.
• This will maintain the bearing pre-load on the shaft bevel gear inside the pinion housing.

-- Place the old inner race/tapered roller bearing -1- into the pinion housing.

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

-- Drive in the new seal using the Seal Installer - Flange Shaft:T10049  .

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• The seal must be flush with the upper edge of the housing.

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

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-- Press the output flange all the way in along with the pinion housing and shaft bevel gear.

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• The shoulder -arrow- of the Press Piece - Multiple Use:VW 455  points to the shaft bevel gear.

-- Install the M8 X 30 mm stud bolts = -A- or Guide Pins - M8:T10273  in the axle drive housing.

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-- Slide a new O-Ring -1- onto the pinion housing -2-.

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

-- Install the previous shim -3-.

-- Carefully install the pinion housing diagonally all the way with Removal Device Pins 2:VW 460/2  .

There is very little space between the pinion housing and the bevel box housing.

The gap is closed when the pinion housing is tightened.

-- Tighten the bolts for the pinion housing -2- diagonally to the tightening specification  OVERVIEW - BEVEL BOX COMPONENTS, 0FV.

-- Coat the threads on the new output flange nut with locking fluid (refer to the Parts Information and tighten it to the tightening specification  OVERVIEW - BEVEL BOX COMPONENTS, 0FV.

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A -  36 mm Socket for ³ /₄ Drive

Radial Run-Out on Output Flange/Shaft Bevel Gear, Measuring

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

-- Secure measuring tools to bevel box with bolt -A- (M8 x 25 mm).

-- Position the Dial Gauge for example Dial Indicator:VAS 6080A  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 -direction of the arrow-.

-- Read the measured value on the Dial Gauge.

• Maximum radial run-out = 0.05 mm.

-- Install the bevel box. Refer to BEVEL BOX, INSTALLING .

-- Check the gear oil level in bevel box. Refer to GEAR OIL, CHECKING LEVEL .