Audi Workshop Service and Repair Manuals

Renewing oil seal for output flange on bevel box

Special tools and workshop equipment required

t	Support clamp -VW 313-

t	Tube -VW 516-

t	Thrust plate -40-105-

t	Thrust piece -T10049-

t	Gearbox support -T10108-

t	Support plate -T10108/1-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/6A-

t	Torque wrench -V.A.G 1601-

t	-1- Two-arm puller Kukko 20/10

t	Three-arm puller Kukko 45/2

t  Multi-purpose tool -VW 771-

t  Extractor tool -VW 771/31-

t  Used oil collection and extraction unit -V.A.G 1782- t  Bolt M10x30 (2x) t  Nut M12x10 (4x)

Procedure l  Tightening torque → Chapter l  Bevel box removed → Chapter. –  Place nut M12x10 -item A- between bevel box and gearbox support -T10108- and fit bevel box on hole marked “4”-arrow- in gearbox support. –  Then align the bevel box with the three remaining holes and secure (place nuts -A- in between). –  Place used oil collection and extraction unit -V.A.G 1782- underneath. –  Drain gear oil out of bevel box.

–  Lock output flange for bevel box in position using support plate -T10108/1- and bolts M10x30 (2x) -arrows-. –  Unscrew nut for output flange. A -  36 mm socket for 3/4" drive –  Swing bevel box so that output flange points upwards.

–  Remove output flange from shaft bevel gear of bevel box. A -  Three-arm puller Kukko 45/2   Note

When pulling off the output flange, the tapered roller bearing inner race remains fitted on the output flange and must be pulled off the output flange separately. –  Place thrust plate -40 - 105- on output flange. –  Pull off inner race for tapered roller bearing from output flange using tapered roller bearing puller -V.A.G 1582- and adapter -V.A.G 1582/6A-.

–  Pull out oil seal -A- for output flange. –  Clean residual locking fluid from thread of shaft bevel gear.

l  Make sure that the shim -2- adjusting the bearing preload of the shaft bevel gear -1- is still fitted. –  Insert inner race for tapered bearing roller -3- into outer race in bevel box. –  Lightly lubricate outer circumference of new oil seal -4- for output flange.

–  Drive in oil seal as far as stop using thrust piece -T10049-. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.

–  Apply puller hooks to bottom of pinion housing and draw in output flange. A -  Two-arm puller Kukko 20/10

–  Coat thread of new nut for output flange with locking fluid and tighten; for locking fluid refer to → Electronic parts catalogue. –  Top up gear oil after installing bevel box → Chapter.