Replacing the radial shaft seal for the drive flange of the front axle differential

Preliminary work 

• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to REMOVING THE REAR DIFFUSER .
• Refer to REMOVING THE UNDERSHIELD ON THE LEFT FUEL TANK .
• Refer to REMOVING UNDERSHIELD ON THE FUEL TANK ON THE RIGHT .
• Refer to REMOVING REINFORCEMENT STRUT .
• Removing rear tunnel connecting support.

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  • Loosen screws (1).
  • Loosen screws (2).
  • Removing rear tunnel connecting support(3).
• Refer to REMOVING EXHAUST SYSTEM .
• Refer to REMOVING THE HEAT SHIELDS .
• Refer to REMOVING TRANSMISSION CROSS-MEMBER .
• Refer to PARTIALLY LOOSENING THE PROP SHAFT .
• Refer to REMOVING THE TRANSFER BOX (ATC 13-1) .
• Refer to REMOVING THE PROP SHAFT FRONT AT THE FRONT AXLE TRANSMISSION .

Remove the input flange of the front axle differential 

• Mark position of nut with respect to shaft with punch marks (arrow).
• Lever out and remove lock plate (1) with a suitable tool.

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• Position special tool 0 492 185 (33 2 140)  with one screw (M8x30) (1) on the drive flange.
• Hand-tighten the screw (M8x30) (2) through the bore on the drive flange with a nut (M8) (3).
• Tighten screw (M8x30) (1) hand-tight.
• Release nut (4). Counter support on the special tool 0 492 185 (33 2 140)  while doing so.

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• Loosen screws (1). Remove the (M8) nut while doing so.
• Remove special tool 0 492 185 (33 2 140)  .

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• Position the special tool 2 466 854  on the drive flange (1).
• Hand-tighten the bolts (2).
• Pull down the drive flange (1) by turning the spindle on the special tool 2 466 854  from the bevel drive pinion and remove it. Counter support with a suitable tool (3) on the special tool 2 466 854  .

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• Cut a small hole in a cloth (1).
• Slide cloth (1) over bevel drive pinion (2).

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• Use thread file (1) to remove the adhesive residue.

Pay attention to the correct thread length without fail! 

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• Thoroughly clean the thread all around on the bevel drive pinion (1) with the thread files (2) from the adhesive residues.
• Clean the thread and the gearing on the bevel drive pinion (1).
• Remove the cloth from the bevel drive pinion (1).

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Removing the radial shaft seal of the drive flange 

• Lift out and remove the radial shaft seal (1) from the front axle transmission using a suitable tool (2).

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• Replace the radial shaft seal for the drive flange of the front axle differential.

Parts:  Radial shaft seal

Installing the radial shaft seal of the drive flange 

• Coat the sealing lips of radial shaft seal with front axle differential oil.
• Use special tool 0 493 539 (31 5 130)  to strike the radial shaft seal up to the stop of the front axle transmission.

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Install the input flange of the front axle differential 

• Clean the gearing on drive flange (1).
• Unscrew the spindle from the special tool 2 466 854  .
• Position the drive flange (1) with the special tool 2 466 854 on the front axle transmission and tap it  with a rubber mallet (2) up to the stop on the drive shaft.
• Loosen screws (3).
• Remove the special tool 2 466 854  .

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• Position special tool 0 492 185 (33 2 140)  with one screw (M8x30) (1) on the drive flange.
• Turn screw (M8x30) (2) through the bore on the drive flange with nut (M8) (3) until hand-tight.
• Tighten screw (M8x30) (1) hand-tight.
• Screw nut (4) to drive shaft by hand.

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• Tighten nut (1) until the punch marks (arrow) on the nut and the drive shaft match. Counter support it using special tool 0 492 185 (33 2 140)  .
• Loosen screws (2). Remove nut (M8) in the process.
• Remove special tool 0 492 185 (33 2 140)  .

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• Replace the lock plate (1).

Parts:  Lock plate

• Position and insert lock plate (1).

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Follow-up work 

• Refer to INSTALLING FRONT PROPELLER SHAFT AT THE FRONT AXLE TRANSMISSION .
• Refer to INSTALLING THE TRANSFER BOX (ATC 13-1) .
• Refer to CONNECTING BATTERY GROUND LEAD .
• Refer to CHECKING/TOPPING UP THE TRANSFER BOX OIL (ACTIVE TORQUE CONTROL 13-1) .
• Refer to CHECK/ADD FRONT AXLE TRANSMISSION OIL .
• Refer to FASTENING THE PROP SHAFT (PARTIALLY REMOVED) .
• Refer to INSTALLING TRANSMISSION CROSS MEMBER .
• Refer to INSTALLING THE HEAT SHIELDS .
• Refer to INSTALLING EXHAUST SYSTEM .
• Installing the rear tunnel connecting support.

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  • Position the connecting support (3) on the rear of the tunnel.
  • Tighten the screws (1).
    TIGHTENING TORQUES
    
    

    Rear connecting support tunnel to body
    M8x30	Snug torque Angle of rotation	28Nm 90°

  • Tighten screws (2).
    TIGHTENING TORQUES
    
    

    Undershield
    Hexagon screw	tightening torque	2.6Nm
    Plastic nut	tightening torque	2.6Nm

• Refer to INSTALLING THE REINFORCEMENT STRUT .
• Refer to INSTALLING UNDERSHIELD ON THE FUEL TANK ON THE RIGHT .
• Refer to INSTALLING THE UNDERSHIELD ON THE LEFT FUEL TANK .
• Refer to INSTALLING THE REAR DIFFUSER .