Renewing seal for flange shaft — AUDI

Gearbox installed

Observe general repair instructions=> Page
00-23
.

Special tools, testers and auxiliary equipment required

Drift VW 195
Drift VW 295
Extractor lever VW 681
Drip tray V.A.G 1306
Puller T10037

Notes:

Removing and installing oil seal on left-hand side is shown below.
The procedure is identical for left and right-hand seals.
Exhaust system does not have to be removed.
Flange shafts without polygon bearings are installed on gearboxes with the letters CPU, CXF and CXZ.
A spacer ring is fitted between the polygon bearing and the differential large bevel gear on flange shafts with 30 mm spline diameter => Page
39-5
.

Removing

Remove heat shield for drive shaft.
Unbolt drive shaft from flange on gearbox.

=> Running Gear, Front and Four-wheel Drive; Repair Group 40; Removing and installing driveshaft
Running Gear, Front and Four-wheel Drive
Removing and installing driveshaft

Turn steering to left onto full lock stop.
Tie up drive shaft as high as possible. Do not damage paint on drive shaft.

Place drip tray V.A.G 1306 underneath the gearbox.

Note:

In order to prevent damaging the needle roller bearing (polygon bearing) or the differential during removal, the flange shaft must be removed evenly, parallel and without applying one-sided force.

Remove flange shaft (left).

Remove the flange shaft, to do this screw the lower support of puller T10037 into the housing (arrow).

Remove the right flange shaft

Remove the flange shaft, to do this screw the lower support of puller T10037 into the housing (arrow).

Always renew flange shaft circlip.
Clamp flange shaft in vice using soft jaws. Use new circlip -A- to press out old circlip from groove in flange shaft.
Pull out flange shaft oil seal with VW 681.

Assembling flange shaft with polygon bearing

1 -
Flange shaft
2 -
Needle roller bearing (polygon bearing)
3 -
Spacer ring
4 -
Circlip
5 -
Spacer ring - fitted additionally on shafts with 30 mm spline diameter

Notes:

If the polygon bearings do not run smoothly with the flange shaft removed, this does notindicate that the bearings are defective. A test for noisy bearings can only be performed with the bearings installed.
Inspect for signs of damage to polygon bearings (such as cracking in outer race).
The polygon bearings can only be replaced together with the flange shaft.
A spacer ring -5- is fitted between the polygon bearing and the differential large bevel gear on flange shafts with 30 mm spline diameter.

Installing

Fill space between sealing and dust lips with a thin layer of multi-purpose grease.
Lightly oil outer circumference of seal.
Knock in new oil seal for right-hand flange shaft to a depth of 5.5 mm below outer surface of housing; keep seal straight when installing

Note:

If the old flange shaft is reinstalled after the repair, the oil seal must be knocked in to a depth of approx. 6.5 mm so that the new seal does not run on the same contact surface as the old one.

Knock in new oil seal for left-hand flange shaft to a depth of 5.5 mm below surface of cover; keep seal straight when installing.

Note:

If the old flange shaft is reinstalled after the repair, the oil seal must be knocked in to a depth of approx. 6.5 mm so that the new seal does not run on the same contact surface as the old one.

Drive in flange shaft using drift VW 295.
Bolt drive shaft to flange shaft.

Fit drive shaft heat shields.
Check oil level in gearbox => Page
34-69
.

Tightening torques

Component · Nm
Drive shaft to flange shaft · M8 · 40
M10 · 70
Drive shaft heat shields · 23