Bevel Box Output Flange Seal, Replacing, Bevel Box Removed

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

The output flange is secured with a nut -A-.

Fig 1: Securing Twelve-Point Nut -A-

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Ignore -B- and -arrows-.

Fig 2: Identifying Special Tools

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Special tools and workshop equipment required

Holding Fixture:VW313
Press Piece - 42mm:VW516
Press Piece - Multiple Use:40-105
Seal Installer - Flange Shaft:T10049
Gearbox Support:T10108
Gearbox Support:T10108/1

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Special tools and workshop equipment required

Torque Wrench 1601:VAG1601
Two-Arm Puller:VAS251001 , or for example Two-Arm Puller:Kukko 20/10
Three-Arm Puller (Kukko 45/2):VAS251205 , or for example Three-Arm Puller:Kukko 45-2
Slide Hammer Set:VW771
Slide Hammer Set - Hook:VW771/37
Sealing Grease
Universal Grease
Refer to the appropriate Electronic Parts Information for the grease allocation.
Two M10 x 30 bolts
Four M12 x 10 nuts

NOTE:

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

-- Remove the bevel box. Refer to BEVEL BOX .

-- Mount the bevel box on the hole marked with the number -5- -arrow- in the Gearbox Support:T10108 .

Fig 3: Identifying Guide Hole, Holding Fixture -VW 313- And Gearbox Support -T10108-

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

-- Align the bevel box to the hole that is opposite it and secure.

-- Place a drip tray underneath.

-- Drain the transmission fluid from the bevel box.

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

Remove Hex Nut for the Output Flange.

Fig 4: Identifying New Output Flange Hex Nut

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A - 36 mm Socket for 3/4 Inch Drive

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

Fig 5: 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 , or for example Three-Arm Puller:Kukko 45-2

-- Remove the output shaft seal -A-.

Fig 6: Identifying Output Shaft Seal

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-- Clean any remaining locking fluid from the thread on the shaft bevel gear.

-- Clean the area around the shaft bevel gear of seal residue.

Installing

Fig 7: Driving In New Sealing Ring To Stop Using Thrust Piece T10049

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-- Drive the new seal in all the way using the Seal Installer - Flange Shaft:T10049 .

-- Fill the space between the sealing lip and the dust lip halfway with Sealing Grease.

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

-- Install the output flange using the Two-Arm Puller -A-.

Fig 8: Identifying 2-Arm Puller Kukko

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A - Two-Arm Puller:VAS251001 , or for example Two-Arm Puller:Kukko 20/10

Note the following:

Use a new removal hook.
To not tilt the output flange.
Mount the hooks on the bottom of the pinion housing.
Tension the removal hook with the Two-Arm Puller -arrows-.
Do not bend the removal hook outward.
Interrupt the procedure if necessary, remove the output flange again and repeat the process.

Coat the threads of new hex nut with locking fluid D 000 600.

Fig 9: Identifying New Output Flange Hex Nut

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-- Tighten the new output flange hex nut to the tightening specification.

Tightening Specification. Refer to -item 14- OVERVIEW - BEVEL BOX COMPONENTS.

A - SW 36 Socket for 3/4 Inch Drive

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

Fig 10: Measure the Radial Run-Out on the Output Flange/Shaft Bevel Gear

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NOTE:

Check the radial run-out on the shaft bevel gear centering pin after tightening the output flange nut.

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

-- Position the Dial Indicator: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 = 0.07 mm.

-- Install the bevel box. Refer to BEVEL BOX .

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

Tightening Specifications

Refer to OVERVIEW - BEVEL BOX COMPONENTS