Renewing seal for output flange on bevel box — AUDI

🧭 Before you start

Fits: VW Caddy III (2K, 2004–2015); platform code 2C0

• Opens: engine oil
• Special tools named: puller

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• AdapterV.A.G 1582/6 may be used in place of adapterV.A.G 1582/6A.

📋 Procedure

1. Remove bevel box .
2. Set bevel box in gearbox support T10108 on hole (arrow) marked with the number (4).
3. Then align bevel box with remaining 3 holes and secure.
4. Place drip tray, e.g. drip tray for workshop hoistVAS 6208 underneath.
5. Drain oil from bevel box.

6. Screw in M10 x 30 bolts (arrows) to lock bevel box output flange with stop plate T10108/1.
7. Remove hexagon nut for output flange.
8. Swing bevel box so that output flange points upwards.
9. Pull output flange off shaft bevel gear of bevel box.
10. Please note different installation positions of seal for output flange:
11. Pull out seal (A) for output flange.
12. Seat thrust pad40-105 on output shaft.
13. Pull inner race of tapered roller bearing off output flange using tapered roller bearing puller. [Note: AdapterV.A.G 1582/6 may be used in place of adapterV.A.G 1582/6A.]
14. Cover pinion housing with a lint-free cloth.
15. Clean residual locking fluid from thread of shaft bevel gear.
16. Lay existing tapered roller bearing inner race (3) in outer race in bevel box.
17. Lightly oil outer circumference of new seal (4) for output flange.
18. Drive in new oil seal with thrust piece T10049.
19. Half-fill space between sealing lip and dust lip with sealing greaseG 052 128 A1.
20. Pull in output flange using two arm puller(A).
21. Fit thrust plate40-105 onto output flange.
22. Using tapered roller bearing puller, pull tapered roller bearing inner race off output flange.
23. Remove seal from output shaft.
24. Unscrew securing bolts for pinion housing (1); then carefully lever pinion housing off cross-wise at projecting edges.
25. Remove pinion housing with shaft bevel gear (2).
26. Clean thread on shaft bevel gear.
27. Fit existing inner race/tapered roller bearing (1) in pinion housing.
28. Lightly oil outer circumference of new seal (2) for output flange.
29. Drive in new oil seal with thrust piece T10049.
30. Half-fill space between dust lip and sealing lip of seal with sealing greaseElectronic Parts Catalogue.
31. Press output flange and pinion housing plus shaft bevel gear together as far as they will go.
32. Screw in M8 x 30 mm studs = (A) or guide pins M8T10273 into final drive housing.
33. Slide new O-ring (1) onto pinion housing (2).
34. Install existing shim (3).
35. Carefully drive in pinion housing cross-wise to stop using boltVW 460/2.
36. Tighten securing bolts for pinion housing (2) cross-wise.
37. Coat thread of new hexagon nut with locking fluid D 000 600.
38. Tighten new nut for output flange.
39. Install bevel box .
40. Fill gear oil into bevel box .

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