Renewing output flange oil seal, 4x2 vehicles with rear-wheel drive — VW

Renewing output flange oil seal, 4x2 vehicles with rear-wheel drive
Special tools and workshop equipment required
Drift sleeve
41-501
Puller hooks
T20143/2
Assembly tool
T40198
Counter-hold tool
T50050
or
counter-hold tool
3145
Socket 34 mm
T50019
2 Bolts M10 x 25
Sealing grease for radial oil seal
Electronic Parts Catalogue
Raise vehicle
Maintenance
Booklet
11
Description of work; Raising vehicle
.
Note
It is not necessary to remove the rear propshaft completely.
Mark position of propshaft
1
relative to gearbox output flange
2
arrows
.
Unscrew bolts
3
of propshaft
1
from gearbox, and remove propshaft from output flange
2
.
Note
Apply the parking brake when loosening the securing bolts of the propshaft.
Tie up propshaft
1
at a suitable location using wire
arrow
.
Release peened points
arrows
on securing nut
1
. This will prevent damage to the thread on the output shaft.
Using two bolts M 10 x 25
arrows
, bolt
counter-hold tool
2
to output flange
1
.
2
-
counter-hold tool
T50050
or
counter-hold tool
3145
3
-
torque wrench
, e.g.
V.A.G 1332
Note
If necessary, fit M 12 nuts onto the M 10 bolts between the
counter-hold tool
and the output flange. This will prevent the
counter-hold tool
from resting against the gearbox carrier.
Unscrew securing nut for output flange using
socket 34 mm
T50019
.
Place
Auffangwanne
under gearbox.
Remove output flange.
Using
puller hook
T20143/2
, pull seal
1
for output flange out of gearbox housing.
Installing
Install in reverse order of removal, observing the following:
Lightly oil outer circumference of new oil seal.
Half-fill space between sealing lip
arrow
and dust lip with
sealing grease for radial oil seal
.
Drive in new seal to stop on gearbox housing using
assembly tool
T40198
. Do not cant oil seal in the process.
The installation dimension in the gearbox housing must be 1 … 2 mm. When using the
assembly tool
T40198
, this dimension is set automatically.
Before installing the output flange, use a screwdriver to remove the old seal
1
from the output flange
2
.
Then, use
drift sleeve
41-501
to carefully drive in new seal to stop.
The mark or the closed side of the seal must face towards the
drift sleeve
.
Before fitting the output flange to the output shaft
2
, make sure that the shim
1
rests on the shoulder of the output shaft. If not, use a screwdriver to carefully push the shim onto the shoulder. Do not damage the seal
3
while doing this.
Push output flange
1
to stop onto output shaft, and screw on new securing nut to stop.
Using two bolts M 10 x 25
arrows
, bolt
counter-hold tool
2
to output flange
1
.
2
-
counter-hold tool
T50050
or
counter-hold tool
3145
3
-
torque wrench
, e.g.
V.A.G 1332
Note
If necessary, fit M 12 nuts onto the M 10 bolts between the
counter-hold tool
and the output flange. This will prevent the
counter-hold tool
from resting against the gearbox carrier.
Using
socket 34 mm
T50019
, tighten securing nut for output flange to specified torque.
Secure nut
1
in the respective recesses on output shaft
arrows
by peening it.
Align propshaft
1
with the mark on output flange
2
arrows
.
Tighten bolts
3
of propshaft
1
on output flange/gearbox
2
to specified torque
Rep. gr.
39
Propshaft; Assembly overview - propshaft
.
Note
Apply the parking brake when tightening the securing bolts of the propshaft.
Finally, check ATF level and top up if necessary
Chapter
.
Specified torque
Component
Specified torque
Securing nut for output flange/gearbox
1)
60 Nm
1)
Renew after each removal