Replacing seal for propellor shaft flange of rear axle — VW

Special tools and equipment required

Drive sleeve 40-20
Counter support 3145
(modified =>Page
39-2
)
Seal extractor 3203
Two-arm puller (commercially available e.g. Kukko 20/10 with hooks)
Caliper gauge with deep scale

Removing

Place collecting tray underneath.
Drain gearbox oil from rear axle.
Mark relative installation position of propshaft and flange.
Unscrew propellor shaft -1- from rear axle flange -2- and secure to prevent it from kinking (tie up).
Check bevel pinion bearing for axial play (no play permitted).

Note:

If there is abrasion (swarf) in the oil or axial play in the pinion bearing, replace the gear set and bearing, since damage to these parts has already occurred.

Mark installation position of collared nut relative to bevel pinion and unlock collared nut -arrow-.
Install counter support 3145 on flange.
Unscrew collared nut.

Pull off flange -1-.

A - two-arm puller, e.g. Kukko 20/10 with hooks

Note:

When pulling out, do not damage the edge of the seat.

Check surface on flange for scores and, if necessary, replace flange.

Pull out seal -1- with seal extractor 3203.

Installing

Fill space between sealing and dust lip with multi-purpose grease.
Drive in new seal -1- flush.
Drive flange onto bevel pinion in accordance with marking with a synthetic head hammer.
Tighten the marked (old) collared nut up to the marking applied previously.

Determine the projection of the bevel pinion -1- relative to the flange -2-.
Unscrew old collared nut and screw on new collared nut until the same projection -a- is achieved (+ 0.5 mm tolerance).

Notes:

Screw on new collared nut in stages with the appropriate measurement of projection -a- until the projection determined is reached.
If the spacer sleeve -3- is overcompressed, i.e. the projection -a- determined is exceeded by more than 0.5 mm, a new spacer sleeve must be installed.

Secure collared nut in the specified manner.
Pour gearbox oil into the rear axle => Page
39-40
.
Install propshaft on flange as marked.