Replacing flange shaft oil seal — AUDI

Gearbox installed

Observe general repair instructions=> Page
00-19
.

Special tools, testers and auxiliary equipment required

Drift VW 195
Drift VW 295
Extractor lever VW 681
Drip tray V.A.G 1306
Two levers

Notes:

Removing and installing oil seal on left-hand side is shown below.
Procedure is identical for left and right-hand seals.
Exhaust system does not have to be removed.
Flange shaft may be with or without a polygon bearing. Assignment => Page
00-3

Removing

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

=> Running gear, Four-wheel drive; Repair group 40; Removing and installing suspension struts and drive shafts
Running gear, Four-wheel drive
Removing and installing suspension struts and drive shafts

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.
Insert two levers -2- behind flange shaft (second mechanic required).
To press off flange shaft, screw in two bolts -1- evenly in opposite threads in flange shaft.

Note:

Flange shaft must be pressed off uniformly and kept in a straight line. Differential housing can break if too much force is applied on one side.

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

Installing

Pack space between sealing and dust lips with 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 old flange shaft is reinstalled after the repair, oil seal must be knocked in to a depth of approx. 6.5 mm so that 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 using VW 195; keep seal straight when installing

Note:

If old flange shaft is reinstalled after the repair, oil seal must be knocked in to a depth of approx. 6.5 mm so that 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.
Checking oil level in manual gearbox => Page
34-41
.

Tightening torques

Component · Nm
Drive shaft to flange shaft · M8 · 40
M10 · 77
Drive shaft heat shields · 23