Replacing oil seals for rear axle shafts — VW

Replacing oil seals for rear axle shafts
Special tools and workshop equipment required
Oil seal extractor lever
VW 681
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Used oil collection and extraction unit
V.A.G 1782
Thrust plate
T50040
Thrust piece
T50041
Sealant
Electronic Parts Catalogue
Hand drill with plastic brush
Safety goggles
Removing
Raise vehicle.
Position
used oil collection and extraction unit
V.A.G 1782
under rear final drive.
Unscrew and remove oil drain plug
arrow
.
Install rear brake carrier
Brake system
Rep. gr.
46
Rear brake; Removing and installing brake carrier
.
Unscrew multi-point socket head bolts
1
.
Pull out rear axle shafts with wheel hub and brake disc.
Remove cover for rear final drive
1
.
Screw in new oil drain plug
arrow
, and tighten it
Item
.
Mark installation position of mounting brackets
1
.
Remove bolts
2
and remove mounting brackets
1
.
Caution
When positioning the
expander
T50040
, pay attention to support points on axle housing
arrows
.
Position
expander
50040
on markings
arrows
.
Note
If the rear axle has high mileage, tighten adjusting bolt to 35 Nm. As needed, increase torque in steps to 70 Nm.
Obtain assistance of a second mechanic in order to remove differential.
Grease thread of setscrew on
expander
T50040
.
Tighten adjuster screw of
thrust plate
T50040
arrow
to max. 70 Nm.
Using a plastic hammer, lightly tap outer bearing races
1
, and remove differential with bearing and shims.
Pull out oil seal
1
on both sides with
oil seal extractor lever
VW 681
.
Installing
Lightly oil outer circumference of new oil seals.
Drive in new seals to stop with
thrust piece
T50041
, being careful not to cant seals.
Fill space between sealing lips
arrow
half full with
sealing grease
Electronic Parts Catalogue
.
Insert differential
3
, outer bearing races
2
and shims
1
with help of a second mechanic.
Note
Bearing and shims on left and right have different diameters.
Install narrower shim on differential side.
Slacken
expander
T50040
and remove.
Install mounting bracket
1
.
Note
Mounting brackets on left and right have different diameters.
Projections on mounting brackets
arrows
must be located over shims.
Screw in bolts
2
, and tighten them
Fig.
.
Clean sensor ring for ABS on wheel hub
arrow
before installing.
Obtain assistance from a second mechanic when installing rear axle shafts.
Insert left rear axle shaft with wheel hub and brake disc.
Note
Make sure that the rear axle shaft engages in the differential. Align the differential if necessary
arrow
.
Insert right rear axle shaft with wheel hub and brake disc.
Screw in bolts
1
, and tighten them to specified torque.
Cover rear final drive with a lint-free cloth.
Use a flat scraper to remove sealant residues from rear final drive housing.
Use a rotating plastic brush, for example, to remove sealant residues from cover for final drive.
The sealing surfaces must be free of oil and grease.
Apply sealant
Electronic part catalog
to cleaned sealing surface on cover for final drive.
Install cover for rear final drive
1
.
Tighten bolts of cover in a diagonal sequence
Item
.
Install brake carrier
Brake system
Rep. gr.
46
Rear brake; Removing and installing brake carrier
.
Fill gear oil in rear final drive
Chapter
.
Specified torques
Chapter
“
Assembly overview - final drive
”
Running gear, axles, steering
Rep. gr.
42
Wheel bearing, trailing arm; Assembly overview - wheel bearing
Brake system
Rep. gr.
46
Rear brake; Assembly overview - rear brake
Mounting bracket
Component
Specified torque
Bolts
2
for mounting bracket
65 Nm