Bevel Box Output Flange Seal, Replacing

WARNING: This page is about a different variant/trim than selected.

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 Indicator 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
Shop Crane - Drip Tray: VAS6208
or Shop Crane - Drip Tray: VAS6208
Sealing Grease
Universal Grease
Refer to the Parts Information for the grease allocation.
M10 x 30 bolts (quantity: 2)
M12 x 10 nuts (quantity: 4)

NOTE:

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

An inner race/tapered roller bearing is located on the bevel box output flange.

It will be removed later on in the procedure.

Do not replace the tapered roller bearing for the bevel box output flange and the shims.

-- Remove the bevel box (refer to BEVEL BOX, REMOVING ) or remove the bevel box from the manual transmission. Refer to Fig 20.

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

Fig 1: Identifying Bevel Box Set On Hole Designated With Number 4 In Gearbox Support T10108

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A - Insert the M12 x 10 nut (quantity: 4) between bevel box and Transmission Holder.

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

-- Place the Drip Tray underneath.

-- Drain the transmission fluid from the bevel box.

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

Fig 2: Securing Twelve-Point Nut -A- By Peenings

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Remove Output Flange Twelve-Point Nut

Fig 3: Identifying New Output Flange Hex Nut

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-- Secure the bevel box output flange using the : T10108/1 . To do so install the M10 x 30 bolts -arrows-.

A - Socket AF 34 mm: T50019

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

Fig 4: Removing Bolts For Pinion Housing

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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.

Fig 5: Insert Suitable Flathead Screwdriver

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

Fig 6: Shaft Bevel Gear

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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.

Fig 7: Output Flange And Pinion Housing

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NOTE:

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

Fig 8: Identifying Output Flange Seal -Arrow-, Removal And Installation

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To remove the seal, the bearing inner race/tapered roller bearing must be removed from the output flange.

Fig 9: Identifying Tapered Roller Bearing Puller V.A.G 1582 And Adapter
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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.

Seal and Output Flange, Installing

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

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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.

Fig 11: Install New Seal

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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

Fig 12: Identifying Inner Race/Tapered Roller Bearing

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The large diameter on the : VW454 faces the output flange.
Only press the inner race/tapered roller bearing until stop.
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-.

Fig 13: Inner Race/Tapered Roller Bearing And Pinion Housing

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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.

Fig 14: Identifying Thrust Disc VW 412, Thrust Tube VW 454, Thrust Tube VW 455 And Thrust Plate VW 401

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

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 in the axle drive housing.

Fig 15: Identifying O-Ring -1-, Pinion Housing -2-, Shim -3- And Stop Plate T10108

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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.

Fig 16: Tightening Bolts

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

Tighten New Output Flange Twelve-Point Nut.

Fig 17: Identifying New Output Flange Hex Nut

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-- Secure the bevel box output flange using the : T10108/1 . To do so install the M10 x 30 bolts -arrows-.

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

A - Socket AF 34 mm: T50019

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

Fig 18: Securing Twelve-Point Nut -A- By Peenings

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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

Fig 19: Measure the Radial Run-Out on the Output Flange/Shaft Bevel Gear

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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 the 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 in direction of -arrow-.

-- Read the measured value on the dial gauge.

Maximum radial run-out = 0.05 mm.

-- Attach bevel box to the manual transmission. Refer to Fig 20 or install bevel box. Refer to BEVEL BOX, INSTALLING .

Fig 20: Identifying Removal/Installation Right Flange Shaft Countersunk Bolt Using Socket And Key T10107

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-- Check the level of the gear oil inside the bevel box. Refer to the appropriate Service Information .

Tightening Specifications

Refer to OVERVIEW - BEVEL BOX COMPONENTS