Output Flange, Removing And Installing, 0FV

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

Fig 1: Identifying Special Toolset: Accessories And Attachments

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Special tools and workshop equipment required

Press Piece - Multiple Use: VW412
Press Piece - Multiple Use: VW454
Press Piece - Multiple Use: VW455
Press Plate: VW401
Two M8 x 30 mm stud bolts or Guide Pins - M8: T10273
Removal Device Pin 2: VW460/2

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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: VAG1582
Puller - Taper Roller Bearing - Adapter 13: VAG1582/13

Special tools and workshop equipment required

Dial Indicator Holder: VW387

Fig 2: Dial Gauge Holder
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Torque Wrench 1601: VAG1601

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Three-Arm Puller (Kukko 45/2): VAS251205

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Dial Indicator: VAS6080A

Fig 3: Dial Gauge - 0-3mm VAS6080
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Sealing Grease. Refer to the Parts Information.
Refer to the Parts Information for the correct locking fluid.
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

Fig 4: Identifying Bevel Box Set On Hole Designated With Number 4 In Gearbox Support T10108

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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-.

Fig 5: Identifying New Output Flange Hex Nut

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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.

Fig 6: Identifying Removal Of Output Shaft From Bevel Box Shaft Bevel Gear

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

A - Three-Arm Puller (Kukko 45/2): VAS251205

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

Fig 7: Identifying Output Flange Seal -Arrow-, Removal And Installation

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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.

Fig 8: Identifying Tapered Roller Bearing Puller V. A. G 1582 And Adapter
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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: VAG1582A and Puller - Taper Roller Bearing - Adapter 13: VAG1582/13 .

-- Remove the output flange seal.

Install the Output Flange Seal

Fig 9: Identifying Pinion Housing -1-, Shaft Bevel Gear -2- And Shim -3-

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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.

Fig 10: Identifying Inner Race/Tapered Roller Bearing -1- And Output Flange Sealing Ring -2-

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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 .

Fig 11: Identifying Thrust Piece 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.

Fig 12: Identifying Oil Seal

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

Fig 13: Identifying Thrust Disc VW 412, Thrust Tube VW 454, Thrust Tube VW 455 And Thrust Plate VW 401

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The shoulder -arrow- of the Press Piece - Multiple Use: VW455 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.

Fig 14: Identifying O-Ring -1-, Pinion Housing -2-, Shim -3- And Stop Plate T10108

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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: VW460/2 .

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 -item : Bolt.

-- Coat the threads on the new output flange nut with locking fluid (refer to the Parts Information) and tighten it to the tightening specification -item : Nut.

Fig 15: Identifying New Output Flange Hex Nut

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A - 36 mm Socket for ³ /₄ Drive

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

Fig 16: Measure the Radial Run-Out on the Output Flange/Shaft Bevel Gear

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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 : 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 in direction of -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 .