Bevel Box Output Flange Seal, Replacing: Notes

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Special Tools And Workshop Equipment Required

Press Plate:VW401
Press Plate:VW402
Press Piece - Rod:VW407
Press Piece - Multiple Use:VW412
Press Piece - Multiple Use:VW454
Press Piece - Multiple Use:VW455
Support Channels:VW457
Press Piece - Reverse Gear Syncro:3296
Gearbox Support:T10108
Gearbox Support:T10108/1
Puller - Taper Roller Bearing:VAG1582 with a short sleeve
Puller - Taper Roller Bearing - Adapter 13:VAG1582/13
Torque Wrench 1601:VAG1601
Seal Installer - Crankshaft:VW204B
Dial Gauge Holder:VW387
Dial Indicator:VAS6080A
Press Piece - Multiple Use:40-105
Socket AF 34 mm:T50019
Two M8 x 30 mm stud bolts or Guide Pins - M8:T10273
Drip Tray:VAG1306
or Shop Crane - Drip Tray: VAS6208
Sealing Grease
Universal Grease
2 M10 x 30 bolts
4 M12 x 10 nuts

NOTE:

Bevel box output flange seal can only be replaced with bevel box removed.

Inner race/tapered roller bearing is located in the output flange bevel box.

These will be removed later in the procedure.

Do not replace the tapered roller bearing for the output flange bevel box and the shim!

-- Remove the bevel box (refer to BEVEL BOX, REMOVING ) or remove the bevel box from the manual transmission. Refer to Figure.

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-- Mount the bevel gear on the hole marked with the number -4- -arrow- in the :T10108 .

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A -Insert the M 12 x 10 nut (quantity: 4) between bevel box and Transmission Holder.

-- Then align bevel box to the remaining three holes and secure.

-- Place the Drip Tray underneath.

-- Drain the transmission fluid from the bevel box.

-- Turn the peenings -arrows- on the twelve point nut -A- back into the output flange recesses -B-.

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Remove Output Flange Twelve-Point Nut

Fig 1: Identifying New Output Flange Hex Nut

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-- Secure the bevel box output flange using the :T10108/1 . Use M10 x 30 bolts -arrows- to lock the flange.

A -

:T50019

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

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-- Remove bolts -arrows- for the pinion housing -A-.

-- Position a suitable flat-head screwdriver -B- into the three recesses -arrows- on the pinion housing -A- and carefully pry out the pinion housing together with the shaft bevel gear.

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-- Place the output flange -A- evenly onto the :VW457 -arrows-.

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

While doing this, secure the shaft bevel gear and inner race/tapered roller bearing to prevent from falling.

-- Remove output flange -A- from pinion housing.

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NOTE:

The seal -arrow- is located on the output flange.

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

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CAUTION:

Danger of damaging the inner race/tapered roller bearing.

•Remove the inner race/tapered roller bearing using the :VAG1582/13 .

•Replace the bevel box if the inner race/tapered roller bearing is damaged.

-- Place the :40-105 on the output flange.

-- Remove the bearing inner race/tapered roller bearing from output flange using the Tapered Roller Bearing Puller.

-- Remove the output flange seal.

Install Seal and Output Flange.

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

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

-- Install new seal so that it is flush.

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The large diameter on the :VW204B faces the seal.
Fill the area between the sealing lip and the seal dust lip halfway with Sealing Grease.

-- Install pinion housing and inner race/tapered roller bearing on the output flange.

-- Press the inner race/tapered roller bearing all the way onto the output flange. Refer to OVERVIEW - BEVEL BOX COMPONENTS

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The large diameter on the :VW454 faces the output flange.
Press the inner race/tapered roller bearing all the way.
Do not apply any greater pressure to the tapered roller bearing.

-- Fit the shim -2-, the inner race/tapered roller bearing -3- and the pinion housing -4- onto the shaft bevel gear -1-.

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Always use the previous shim -2- to reinstall.
This ensures the bearing pre-load of the shaft bevel gear in the pinion housing.

-- Lightly apply Universal Grease to the output flange splines.

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

The shoulder -arrow- of the :VW455 points to the shaft bevel gear.
Turn the pinion housing during pressing procedure.

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

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-- Coat the new O-ring -1- with gear oil and slide it onto the pinion housing -2-.

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

-- Install the previous shim -3-.

-- Tighten the bolts -1- alternating in small steps, all the while turning the output flange -2- back and forth gently.

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-- Tighten the bolts for the pinion housing -2- diagonally.

Tighten New Output Flange Twelve-Point Nut.

Fig 2: Securing New Output Flange Hex Nut

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-- Secure the bevel box output flange using the :T10108/1 . Use M10 x 30 bolts -arrows- to lock the flange.

-- Tighten the new twelve-point nut for the output flange. Refer to OVERVIEW - BEVEL BOX COMPONENTS .

A -

:T50019

-- Secure the twelve-point nut -A-.

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-- Nut is offset by 120°, cover in the beading -B- on the output shaft with peen -arrows-.

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

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NOTE:

The radial run-out on the shaft bevel gear alignment pin must be checked after tightening the output flange nut.

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

-- Position the :VAS6080A on the shaft bevel gear alignment pin -B- and set the 1 mm pre-tension to "0".

-- Turn the output flange one complete rotation direction of -arrow-.

-- Read the measured value on the gauge.

Maximum radial run-out = 0.05 mm.

-- Attach bevel box to the manual transmission. Refer to Figure or install bevel box. Refer to BEVEL BOX, INSTALLING .

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-- Check the level of the axle oil inside the bevel box. Refer to BEVEL BOX GEAR OIL LEVEL, CHECKING .