Replacing seal for flange shaft — AUDI

01AA
(Gearbox installed)

Observe general repair instructions=> Page
00-17
.

Special tools and workshop equipment required

VW 295 Drift
VW 681 Release lever
2062 Drift
T10037 Puller
V.A.G 1331 Torque wrench
V.A.G 1332 Torque wrench

Removing

Turn steering to left onto full lock stop.

When replacing right sealing ring:

Detach heat shields -arrow 1- and -arrow 2- above the right-hand drive shaft.

When replacing left sealing ring:

If fitted, remove splash plate -arrows- above left drive shaft.

All models:

Unbolt drive shaft -1- from flange shaft.
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 flange shaft. For this purpose, screw in lower support of puller device T10037 into the housing (arrow).

Removing right flange shaft

Remove flange shaft. For this purpose, screw in lower support of puller device T10037 into the housing (arrow).

All models:

Pull out flange shaft oil seal with VW 681.

Installing

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.

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 bevel gear on flange shafts with 30 mm spline diameter.

When replacing right sealing ring:

Lightly oil outer circumference of sealing ring.
Drive 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 driven 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.

When replacing left sealing ring:

Lightly oil outer circumference of sealing ring.
Drive 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 driven 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.

All models:

Pack space between sealing and dust lips with sealing grease G 052 128 A1.
Drive in flange shaft using drift VW 295.
Bolt drive shaft to flange shaft.

=> Running Gear, FWD and 4WD; Repair group 40
Running Gear, FWD and 4WD

Bolt on cover plates for drive shaft if present.
Top up oil in manual gearbox and check oil level => Page
34-56
.

Tightening torques

Component · Nm
Heat shields for drive shafts to gearbox · 23