Bevel Box Drive Flange Seal

Bevel Box Drive Flange Seal

Special tools, testers and auxiliary items required

• Holding Fixture (VW 313)

• Tube 42 mm Dia. (VW 516)

• Thrust Piece (40-105)

• Thrust Piece (T10049)

• Transmission Support (T10108)

• Stop Plate (T10108/1)

• Tapered Roller Bearing Puller (V.A.G 1582)

• Attachment to VAG 1582 (V.A.G 1582/6A)

• Torque wrench (V.A.G 1601)

• Kukko 20/10 two-arm puller

• Kukko 45/2 three arm puller

• Slide Hammer-Complete Set (VW 771)

• Pulling Hook (VW 771/31)

• Oil Collecting and Extracting Device

• M10 x 30 bolt (quantity: 2)

• M12 x 10 nut (quantity: 4)

Procedure






• Tightening specification, refer to => [ Flange Shaft, Seals and Bracket on Bevel Box Overview ] Description and Operation.

- Remove the bevel gear. Refer to vehicles with 2.0 TFSI engine=> [ Bevel Box ] Bevel Box or vehicles with 3.2L MPI engine=> [ Bevel Box ] Bevel Box.

- Place the bevel box on the hole "4" marked with an - arrow - in the (T10108) while laying the M12 x 10 nut - A - between the bevel box and transmission holder.

- Align the bevel box with the remaining 3 holes and secure it with the nut - A -.

- Place the (V.A.G 1782) underneath.

- Drain the axle oil from the bevel box.

- Bevel box output shaft with (T10108/1) , install the two M10 x 30 bolts - arrows -.






- Remove the output flange nut.

A Socket SW 36

- Pivot bevel box so that the output shaft faces upward.

- Remove the output flange from the bevel box shaft bevel gear.






A Kukko 45/2 three arm puller

• When removing output shaft, inner race/tapered roller bearing remains on the output shaft and must be removed from it.






- Place the (40 - 105) on the output flange.

- Remove the tapered roller bearing inner race from the output flange using (V.A.G 1582) and (V.A.G 1582/6A).

- Remove output shaft seal - A -.






- Clean any remaining locking fluid from the thread on the shaft bevel gear.

• Previous shim - 2 - for shaft beveled gear preload - 1 - must be installed.






- Place the tapered bearing inner race - 3 - into the outer race inside the bevel box.

- Lightly coat the outer circumference of the new output flange seal - 4 - with oil.

- Drive in shaft seal as far as the stop with (T10049).






- Fill the space between the sealing- and dust lip half way with sealing grease; for the correct sealing grease, refer to the Electronic Parts Catalog (ETKA).

- Pull the output flange inward; when doing this mount the pulling hooks at the bottom of the drive pinion housing.






A Kukko 20/10 two-arm puller

- Coat the new nut for the output flange with locking fluid and then tighten; for the correct locking fluid, refer to the Electronic Parts Catalog (ETKA).






- Install the bevel box. Refer to vehicles with 2.0 TFSI engine=> [ Bevel Box ] Bevel Box or vehicles with 3.2L MPI engine=> [ Bevel Box ] Bevel Box.

- Add gear oil to the bevel box. Refer to => [ Axle Oil, Draining, or Filling after Repairs ] Axle Oil, Draining, or Filling After Repairs.