Output Flange, Removing And Installing, 0CN

WARNING: This page is about a different car, the 2023 Volkswagen Arteon. However, it is still accessible from the selected car via links, so may be relevant.

Characteristics of the bevel box. Refer to BEVEL BOX, DIFFERENTIATING .

Fig 1: Identifying Special Tools

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Special tools and workshop equipment required

Press Plate:VW 401
Press Plate:VW 402
Press Piece - Rod:VW 407
Press Piece - Multiple Use:VW 412
Press Piece - Multiple Use:VW 454
Press Piece - Multiple Use:VW 455

Fig 2: Identifying Special Tools

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Special tools and workshop equipment required

Support Channels:VW 457
Press Piece - Reverse Gear Syncro:3296
Gearbox Support:T10108 with Gearbox Support - Stop Plate:T10108/1
Puller - Taper Roller Bearing:V.A.G 1582
Puller - Taper Roller Bearing - Adapter 13:V.A.G 1582/13
Torque Wrench 1601:V.A.G 1601

Special tools and workshop equipment required

Seal Installer - Crankshaft:VW 204 B

Fig 3: Identifying Seal Installer - Crankshaft VW204B
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Dial Indicator Holder:VW 387

Fig 4: Dial Gauge Holder
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Press Piece - Multiple Use:40 - 105

Fig 5: Press Piece - Multiple Use 40-105
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Socket AF 34 mm:T50019

Fig 6: Identifying Socket AF 34 mm T50019
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Dial Indicator:VAS 6080A

Fig 7: Dial Gauge - 0-3mm VAS6080
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Sealing Grease. Refer to the appropriate Electronic Parts Information.
M10 x 30 bolt (quantity: 2)
M8 x 25 bolt (quantity: 1)
M12 x 10 nut (quantity: 4)

Removing

A tapered roller bearing inner race 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.

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

-- Place the bevel box on the hole -arrow- marked with the number "4" in the Gearbox Support:T10108 . Place the M12 x 10 nut -item A- between the bevel box and the transmission holder to do so.

Fig 8: Identifying Bevel Box Set On Hole Designated With Number 4 In Gearbox Support T10108

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-- Align the bevel box with the remaining three holes and secure it with the nuts -A- inserted between.

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

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

Fig 9: Securing Twelve-Point Nut -A-

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

Fig 10: Identifying New Output Flange Hex Nut

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A - Socket AF 34 mm:T50019

-- Remove the output flange nut.

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

Fig 11: Removing Bolts For Pinion Housing

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-- Remove the 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 12: Insert Suitable Flathead Screwdriver

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-- Place the output flange -A- evenly onto the Support Channels:VW 457 -arrows-.

Fig 13: Shaft Bevel Gear

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

Secure the shaft bevel gear and tapered bearing inner race from falling.

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

Fig 14: Output Flange And Pinion Housing

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

Fig 15: Identifying Output Flange Seal -Arrow-, Removal And Installation

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The tapered bearing inner race must be removed from the output flange to remove the seal.

Fig 16: Identifying Tapered Roller Bearing Puller V. A. G 1582 And Adapter
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CAUTION:

Risk of damaging the tapered bearing inner race.

Remove the tapered bearing inner race using the Puller - Taper Roller Bearing - Adapter 13:V.A.G 1582/13 .

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

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

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

-- Remove the output flange seal.

-- Insert the old tapered bearing inner race -1- into the pinion housing.

Fig 17: 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-.

-- Install the seal so that it is flush.

Fig 18: Install New Seal

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The larger diameter of the Seal Installer - Crankshaft :VW 204 B points to the seal.

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

-- Install the tapered bearing inner race (refer to OUTPUT FLANGE, REMOVING AND INSTALLING, 0CN ) all the way onto the output flange.

Fig 19: Identifying Inner Race/Tapered Roller Bearing

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The larger diameter of the Press Piece - Multiple Use :VW 454 points to the output flange.
Install the tapered bearing inner race until it stops. Do not apply any greater pressure to the tapered roller bearing.

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

Fig 20: Inner Race/Tapered Roller Bearing And Pinion Housing

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Re-install the old shim -2-. This ensures the bearing pre-load of the shaft bevel gear in the pinion housing.

-- Carefully press the pinion housing with the output flange all the way onto the shaft bevel gear.

Fig 21: 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:VW 455 points to the shaft bevel gear.
Turn the pinion housing during pressing procedure.

-- Align the old shim -3- to the pinion housing -2-.

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

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

-- Insert the pinion housing -2- into the axle drive housing -4-.

Note:

The splines on the shaft and head bevel gear must come in contact.
Align the openings for the pinion housing bolts to the axle drive housing.

-- Tighten the bolts -1- in small steps, alternating from side to side. While doing so, turn the output flange -2- back and forth slightly -arrows-.

Fig 22: Tightening Bolts

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-- Tighten the bolts -arrows- for the pinion housing -A- in a diagonal sequence.

Fig 23: Removing Bolts For Pinion Housing

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-- Tighten the new output flange twelve-point nut.

Fig 24: Identifying New Output Flange Hex Nut

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A - Socket AF 34 mm:T50019

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

Fig 25: Securing Twelve-Point Nut -A-

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-- With the nut offset by 120° (248 °F), move it into the output flange depressions -B- -arrows-.

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

Fig 26: 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.

-- Fasten the measuring tools to the bevel box using a M8 x 25 bolt -item a-.

-- Position the 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 -arrow-.

-- Read the measured value on the dial gauge.

Radial run-out: maximum 0.05 mm.

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

-- Fill the gear oil. Refer to GEAR OIL, DRAINING AND FILLING .

Tightening Specifications

Refer to OVERVIEW - BEVEL BOX COMPONENTS