Differential Shaft Seal

Differential Shaft Seal

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Insert Tool (T10023)

• Assembly Tool (T40107)

• Pry lever

• Cleaning solution (D 009 401 04)

Removing

• The differential shaft seal can be replaced with transmission installed.

- Drain the ATF. Refer to => [ ATF, Draining for ATF Flush ] ATF, Draining for ATF Flush.

- Remove the differential. Refer to => [ Differential ] 01J,0AN Continuously Variable Transmission

- Remove the right flange shaft.

• In the case of insufficient accessibility in the vehicle, right flange shaft must not be completely removed. In that case, it only needs to be pulled out of transmission housing a little in order to create enough room to remove and install shaft seal.


• In the following procedures, the differential shaft surface must not come in contact with hard objects. Even small scratches or damage to the differential shaft sealing surface cause lack of seal and the transmission must be replaced completely.

- Place a punch on a side hole of pinion shaft seal and punch a small hole - arrow - to install a metal screw in shaft seal.





- Install metal screw with large head in shaft seal.





- Use a stable lever - 1 - with center notch - arrow - to install metal screw.





- Position lever on metal screw.


Place a piece of wood or a plastic plate - 2 - between the lever and the transmission housing to prevent damage.

• The housing must not be damaged.

- Remove the shaft seal.

Installing

- Check the differential shaft for wear. Refer to => [ Differential Shaft, Checking for Wear ] Differential Shaft, Checking for Wear.

- Clean breather tube - arrow - using pressurized air and lay a cloth on interior side of breather tube.





- Clean the differential shaft sealing surface - arrow - with cleaning solution (D 009 401 04) and a soft cloth; to do so turn differential shaft.





• Selector shaft lever must not be in position P.

- Remove stubborn deposits with the fingernail - do not use tools at all.


• Do not clean the differential shaft mechanically with tools or polishing paste under any circumstances. Even small scratches or damage to the differential shaft sealing surface cause lack of seal and the transmission must be replaced completely.

- Coat the outside circumference of the shaft seal with ATF.

- Check the assembly aid (T40107/2) for cracks or burrs. Do not use a damaged assembly aid.

- Place (T40107/2) on pressure sleeve (T40107/1) and slide shaft seal - 1 - onto pressure sleeve.





• Closed side of shaft seal points towards tool.

- Remove (T40107/2).

- Connect (T40107/1) with shaft seal - 1 - to differential shaft.

- Place transmission shift lever in P position (all the way back).





- Rotate nuts on spindle (T40107/3) all the way back.

- Rotate (T40107/3) to stop with open-end wrench.

• This installs spindle securely on differential shaft.

- Bring (T40107/1) into correct position.

• Tabs - arrows - pressure sleeve circumference must engage in notches on transmission housing.

- Press shaft seal into transmission housing with pressure sleeve and tighten nut to 17 Nm using (V.A.G 1331) and (T10023).





• Shaft seal must settle for 2 minutes.

- After waiting 2 minutes, remove the nut and remove the pressure sleeve in drive direction.

- Check whether shaft seal lip visible from outside lies on cylindrical differential shaft sealing surface and not on chamfer - arrow -; press shaft seal on, if necessary





- Install the right flange shaft.

- Install differential housing and front final drive cover => [ Differential ] 01J,0AN Continuously Variable Transmission.

• With transmission removed:

• In order to be able to perform a test drive, the transmission must be installed in the vehicle to check for leaks.

- Fill the ATF. Refer to => [ ATF, Filling for ATF Flush ] ATF, Filling for ATF Flush.

- Perform an extended test drive and finally check for leaks on bleeder hole - arrow A - on front final drive cover.





• The bleeder hole is covered with a protective plate in certain transmissions.

• On new front final drive covers, the ventilation opening has been relocated to the lowest bolt - arrow - (inner oil canal); a leak is visible only from underneath on the front final drive cover.

• If oil escapes at the bleeder hole, repair must be repeated.