Differential Oil Seal & Bearing For Propeller Shaft Flange

1. On V8 Quattro models, Remove main/rear muffler and retainers, then the heat shields.
2. Remove fuel tank cover, then the support for exhaust system.
3. Place an oil drain pan underneath differential and drain oil.
4. Scribe a mark on propeller shaft and differential flange prior to disassembly, then disconnect and tie up propeller shaft.
5. On 100/200 models, remove cover.
6. Disconnect front parking brake cable.
7. On V8 Quattro models, remove parking brake cable bracket.
8. Support differential with transmission jack VAG 1383/A or equivalent, then remove crossmember and carefully lower differential.
9. Remove differential bracket from differential, then the differential cover bolts.
10. Remove differential cover using a suitable slide hammer.
11. Using a suitable press and holding fixture, press sleeve off, then remove small circlip.
12. Press flange off, then pry out seal using prying tool VW 681 or equivalent.
13. Clean seat for oil seal. Do not use solvent.
14. Remove large circlip, then press bearing out.
15. Press new bearing in, then install large circlip.
16. Install oil seal with washer 020 311 391 F or 016 311 391 P (.04 inch thickness) onto drift 2005 or equivalent. Fill space between oil seal lips with multi-purpose grease.
17. Drive oil seal in until seated, then remove drift and washer.
18. Press flange in, then install small circlip.
19. Install sleeve by driving on with plastic hammer, If necessary press on with punch VW 407 or equivalent.
20. Install cover with new O-ring, then the flange. Torque differential cover bolts to 18 ft. lbs.
21. Install differential bracket, then raise differential and install crossmember.
22. On V8 Quattro models, install parking brake cable bracket.
23. Connect front parking brake cable.
24. On 100/200 models, install cover.
25. Install propeller shaft, then fill differential as necessary.
26. On V8 Quattro models, Install support for exhaust system, then the fuel tank cover.
27. Install heat shields, then the main/rear muffler and retainers.
28. Torque propeller shaft to flange bolts to 40 ft. lbs., differential to crossmember to 32 ft. lbs. and bracket to differential bolts to 18 ft. lbs.