399219 Removing and Installing Sealing Ring For Front Transfer Box Output

WM 399219 Removing and installing sealing ring for front transfer box output

Tools













Technical values






Preliminary work for transfer box sealing ring

1. Remove front cardan shaft. -> 390219 Removing and installing front cardan shaft - section on "Removing" 390219 Removing and installing front cardan shaft
2. Support transfer box with transmission jack.
3. Support transmission with material 00000 and secure with retaining band.
4. Unscrew four exhaust system screws on the cross member -centre arrow- and unscrew screw connection holder on body -right arrow-.





Exhaust system at cross member

5. Unscrew transmission cross member on body -A-.





Transmission cross member

6. Unscrew two screws on the cross member -B- on the transfer box holder and remove transmission cross member.

Removing sealing ring for front transfer box output





Overview of sealing ring for front transfer box output

1. Unscrew collar nut of output flange with special tool socket t10204. To do this, block flange with special tool arm bracket 3435.





Countering flange

2. Remove round seal on output flange.





Round seal on output flange

3. Remove output flange with shop made tool and striker VW 771/1.





Removing output flange

4. Remove sealing ring with special tool hook VW 681.





Removing sealing ring

Installing sealing ring for front transfer box output





Overview of sealing ring for front transfer box output

Information

- Ensure that the round seal -arrow- is inserted.





Round seal on output flange

- Replace nut on output flange.

- Fit nut using screw-locking compound, e.g. Loctite 648.

1. Drive in new sealing ring with special tool pressure piece T10185 => Driving in the sealing ring until the special tool touches the transmission housing.





Driving in the sealing ring

2. Install output flange and, if necessary, drive in with a plastic hammer.

Information

- Ensure that the round seal -arrow- is inserted.





Round seal on output flange

- Replace nut on output flange.

- Fit nut using screw-locking compound, e.g. Loctite 648.

3. Screw in new nut on output flange using special tool socket T10204. To do this, counter the flange with special tool arm bracket 3435. => Tightening torque: 100 ftlb.





Tightening nut on output flange

4. Caulk nuts at the recesses in the output shaft.





Caulking nuts

Subsequent work for sealing ring for transfer box

1. Install front cardan shaft. -> 390219 Removing and installing front cardan shaft - section on "Installing" 390219 Removing and installing front cardan shaft
2. Screw in new transmission cross member screws -B- on transfer box holder. => initial tightening: 50 Nm (37 ftlb.) => final tightening: 90 angular °





Transmission cross member

3. Screw in new cross member screws on body -A-. => initial tightening: 50 Nm (37 ftlb.) => final tightening: 90 angular °
4. Fix exhaust system to transmission cross member -centre arrow- and body -outer arrow-. Observe tightening torques for exhaust system -> 260119 Removing and installing exhaust system Testing and Inspection





Exhaust system to cross member

5. Check oil for transfer box. -> 39903500 Checking and topping up oil for transfer box Testing and Inspection