Drive Shaft Flange Seal, Replacing

Drive shaft flange seal, replacing





The following special tools and testing devices are required:
^ V.A.G 1383A Engine/transmission jack with universal mounting V.A.G 1359/2
^ 3028 - Retainer
^ VW 391 - Puller
^ VW 771 - Slide hammer-complete set
^ VW 771/37 - Additional part for VW 771
^ 3026 - Mandrel





^ Drive pinion 3143
^ Rear final drive installed

- Observe general repair instructions

Removing
- Remove rear section of exhaust system as from clamp(s):





- Check whether there is a factory marking (paint dot) on drive shaft. If you do not find one, mark the position of the constant velocity joint -arrow A- relative to the rear final drive -arrow B-with a colored dot.
- Disconnect drive shaft from rear final drive and tie it up to exhaust system brackets.
- Place engine/transmission jack VAG 1383 A with universal transmission mounting 1359/2 under final drive and secure final drive.





- Remove securing bolts -arrows- of left final drive support.
- Carefully lower final drive until flange is freely accessible.
- Color-mark the position of the securing nut for the drive pinion.





Calculate dimension "a" and dimension "b"
^ Distance of flange to drive pinion =

Dimension a

^ Distance of flange to securing nut for the drive pinion =

Dimension b

- Note calculated dimensions
- Count turns when unscrewing the securing nut and make a note of them.

Note:
^ Illustrations show the final drive removed for the following procedure.





- Install support tool 3028 and remove drive pinion nut.
- Place drip tray underneath to collect oil.





- Detach flange with removal tool VW 391.

A - Screw in two hex bolts M8 x 30 into flange.





- Remove sealing ring.

Installing
Installation is carried out in reverse order. Note the following:





- Replace O-ring between drive pinion bearing and flange.
- Lightly oil O-ring before installing.
- Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.
- Lightly oil outer circumference of seal.





- Drive in seal for drive shaft flange onto stop with drift 3026.





- Drive drive shaft flange onto drive pinion until securing nut can be mounted.

Note:
Use the old hex nut to reattach the flange to the drive pinion. Otherwise the original installed position will not be relocated.

- Clean drive pinion nut and threads on drive pinion of oil and grease residues. Thinly coat threads with locking fluid D 000 600.

Note:
The number of turns when reattaching must be the same as during unscrewing.





Perform control measurement - check dimension "a" and dimension "b".

Note:
^ O-ring -1- must be installed when measuring.

^ The hex nut must be returned to exactly the marked position.

^ Maximum permissible deviation from original measurements: ± 0.3 mm.





- Lock hex nut.
- Move final drive back to installation position.





- Screw final drive to front mounting bracket -arrows-.
- Top off gear oil in rear final drive and check oil level.
- If there was a factory marking at the drive shaft determine now the radial run-out at the flange/drive shaft. Attach drive shaft in such a way that the color coding at the drive shaft are aligned with new marking at flange.
- If the position of the drive shaft relative to the flange/drive shaft were marked before removal the drive shaft must be reattached at same position.

Observe installation instructions
- Replace seal on drive shaft flange and tighten drive shaft to torque.
- Stress-free alignment of exhaust system:

Tightening torques