Audi Workshop Service and Repair Manuals

Renewing oil seal and grooved ball bearing for flange shaft (left-side)

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Oil seal extractor lever -VW 681-

t	Tube -32 - 109-

t  Tube -2040-

t  Drift -3384-

t  Used oil collection and extraction unit -V.A.G 1782- Procedure   Note t  General repair instructions → Chapter. t  Observe rules for cleanliness when working on automatic gearbox → Chapter.

–  Loosen bolt -arrow- securing drive shaft to wheel hub (left-side) with vehicle standing on its wheels. –  Remove front left wheel.

–  Vehicles with 2.5 ltr. TDI engine: detach drive shaft noise insulation (left-side) from wheel housing -arrows-.

–  Remove heat shield for drive shaft (left-side) -arrows-.   Note The third bolt is not shown in the illustration. –  Unbolt drive shaft -1- (left-side) from flange shaft on gearbox → Rep. Gr.40.

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Unscrew oil filler plug -arrow- and extract at least 0.5 ltr. of gear oil from final drive.   Note It is essential to extract oil from the final drive as there is otherwise a danger of mixing gear oil with ATF. –  If fitted, remove speedometer sender -G22- → Chapter. –  Unbolt retainer for electrical connector from bearing bracket for flange shaft.

–  Unbolt flange shaft bearing bracket -arrows-. –  Pull out flange shaft.   Note When the gearbox is in the vehicle it is possible to pull out the flange shaft (left-side) between the body and the subframe by rotating the bearing bracket for the flange shaft approx. 60° to the right away from the installation position.

–  Remove circlip -arrow A- for grooved ball bearing.

–  Press flange shaft out of flange shaft bearing bracket. –  Pull out flange shaft oil seal using oil seal extractor lever -VW 681-.

–  Press grooved ball bearing out of bearing bracket.

–  Press new grooved ball bearing into bearing bracket. –  Lightly lubricate outer circumference and sealing lip of oil seal with gear oil.

–  Drive in new oil seal until thrust piece contacts stop, ensuring that seal remains straight. l  Installation position: open side of oil seal points towards gearbox

–  Gearbox with speedometer sender -G22-: Fit drive wheel for -G22- onto flange shaft -arrow-. l  Installation position: the coupling lugs on the drive wheel must engage in the slots on the flange shaft.   Note If necessary, apply grease to the contact surface in order to hold the drive wheel in position.

–  Press bearing bracket with grooved ball bearing onto flange shaft.

–  Insert circlip -arrow A-.

–  Renew O-ring -arrow B- in bearing bracket for flange shaft.

–  Check that there are no sharp edges on gearbox end of flange shaft -arrow-; deburr edges if necessary. –  Insert flange shaft (left-side) into the gearbox.   Note While pushing in the flange shaft (left-side), it must be guided carefully by hand to avoid damaging the twin-lip oil seal in the gearbox. The remaining installation steps are carried out in reverse sequence; note the following: –  Bolt drive shaft to flange shaft (left-side) → Rep. Gr.40. –  Install front wheel → Rep. Gr.44. –  Fill up gear oil in front final drive → Chapter. Tightening torques

Component	Nm
Bearing bracket for flange shaft (left-side) to gearbox	23
Heat shield for drive shaft to gearbox	23