Renewing output flange oil seal on bevel box "0CN": Audi A3 / Q3

🧭 Before you start

Fits: Audi A3 (8V, 2012–2020), Audi Q3 (8U, 2011–2018); platform codes 84, FV

• Opens: gearbox oil
• Special tools named: VAS 6080, puller, dial gauge

Don't miss

• Oil seal (arrow) is located on output flange.
• Teeth of shaft bevel gear and bevel gear must mesh.Align holes for securing bolts on pinion housing with final drive housing.
• After tightening nut for output flange, check radial run-out at centring pin of shaft bevel gear.

📋 Procedure

1. Detach bevel box from gearbox .
2. Locate bevel box on hole marked "“4”"(arrow) in gearbox support T10108. To do so, place nuts M12x10 (item A) between bevel box and gearbox support.
3. Then align the bevel box with the three remaining holes and secure (place nuts (A) in between).
4. Position drip tray, e.g. drip tray for workshop hoistVAS 6208 below.
5. Drain gear oil out of bevel box.

6. Drive back peening points (arrows) of twelve-point nut (A) in recesses of output flange (B).
7. Lock bevel box output flange with support plate T10108/1 by screwing in two M10x30 bolts (arrows).
8. Remove output flange nut.
9. Swing bevel box so that output flange points upwards.
10. Remove securing bolts (arrows) for pinion housing (A).
11. Apply a suitable plain slot screwdriver (B) to 3 recesses (arrows) on pinion housing (A) and carefully lever off pinion housing together with shaft bevel gear.
12. Fit output flange (A) onto support railsVW 457(arrows) so that it positioned centrally.
13. Press shaft bevel gear off output flange (A).
14. Press output flange (A) out of pinion housing. [Note: Oil seal (arrow) is located on output flange.]
15. ⚠ Take care not to damage tapered roller bearing inner race.Pull off tapered roller bearing inner race using adapter for tapered roller bearing pullerV.A.G 1582/13.Bevel box must be renewed if tapered roller bearing inner race is damaged. — Place thrust plate40 - 105 on output flange.
16. Pull off tapered roller bearing inner race from output flange using tapered roller bearing puller.
17. Remove oil seal for output flange.
18. Insert old tapered bearing roller inner race (1) into pinion housing.
19. Lightly lubricate outer circumference of new oil seal (2) for output flange.
20. Press in new oil seal so that it is flush.
21. Pack space between sealing lip and dust lip of oil seal half-full with sealing greaseG 052 128 A1.
22. Press tapered roller bearing inner race onto output flange as far as stop.
23. Fit shim (2), tapered roller bearing inner race (3) and pinion housing (4) onto shaft bevel gear (1).
24. Carefully press pinion housing with output flange onto shaft bevel gear as far as stop.
25. Align old shim (3) with pinion housing (2).
26. Lightly lubricate new O-ring (1) with gear oil and fit onto pinion housing (2).
27. Place pinion housing (2) in final drive housing (4). [Note: Teeth of shaft bevel gear and bevel gear must mesh.Align holes for securing bolts on pinion housing with final drive housing.]
28. Tighten bolts (1) in small steps and alternating between sides; at the same time turn output flange (2) slightly back and forth in direction of (arrows).
29. Tighten securing bolts (arrows) for pinion housing (A) to final setting in a diagonal sequence.
30. Tighten new twelve-point nut for output flange.
31. Secure twelve-point nut (A).
32. Peen nut into recesses of output flange (B) (120° offset) (arrows). [Note: After tightening nut for output flange, check radial run-out at centring pin of shaft bevel gear.]
33. Secure measuring equipment to bevel box with bolt (A) (M8 x 25 mm).
34. Apply dial gauge, e.g. VAS 6080 to centring pin of shaft bevel gear (B) and set to "“0”" with 1 mm preload.
35. Turn output flange one complete rotation in direction of (arrow).
36. Check reading on dial gauge.
37. Attach bevel box to gearbox .
38. Check gear oil level in bevel box 6-speed manual gearbox39Gear oil; Checking gear oil level.

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