Volkswagen Workshop Service and Repair Manuals

Renewing oil seal for propshaft drive flange at 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  Multipurpose tool -VW 771-

t  Puller hooks VW 771/37

t  Used oil collection and extraction unit -V.A.G 1782- t  Sealing grease -G 052 128 A1- t  2 bolts M10x30 t  4 nuts → M12 x 10 Procedure   Note The oil seal for the output flange of the bevel box can be renewed only with the bevel box removed. –  Remove bevel box:    Golf 2004 ►, with 3.2 l - V6 engine, Passat 2006 ►, with 3.6 l - V6 engine → Chapter    Passat CC 2009 ►, CC 2010 ► Passat 2011 ► with diesel engine → Chapter

–  Set bevel box in gearbox support -T10108- on hole -arrow- marked with the number -4-. A -  Lay nuts → M12 x 10 (Qty. 4) between bevel box and gearbox support. –  Then align bevel box with remaining 3 holes and secure. –  Put used oil collection and extraction unit -V.A.G 1782- underneath. –  Drain oil from bevel box.

–  Lock bevel box output flange with stop plate -T10108/1-, screwing in M10x30 bolts -arrows-. –  Remove hexagon nut for output flange. A -  36 mm socket for 3/4" drive –  Swing bevel box so that output flange points upwards.

–  Pull output flange off shaft bevel gear of bevel box. A -  Three arm puller, e.g. KUKKO 45-2   Note Tapered roller bearing inner ring remains on output flange when output flange is pulled off. Inner ring is then pulled off output flange → Anchor. –  Place thrust plate -40-105- on output flange.

–  Pull inner tapered roller bearing race off output flange using tapered roller bearing puller.   Note Grip -V.A.G 1582/6A- may be used in place of grip -V.A.G 1582/6-.

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

l  Old shim -2- for preloading bearing of shaft bevel gear -1- must be installed. –  Lay tapered roller bearing inner race -3- in outer race in bevel box. –  Lightly oil outer circumference of new seal -4- for output flange.

–  Drive in new oil seal to stop using thrust piece -T10049-. –  Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1-.

–  Pull on output flange using two arm puller -A-. A -  Two arm puller, e.g. KUKKO 20/10 –  Apply puller hooks to underside of pinion housing for this purpose. –  Coat thread of new hexagon nut with locking fluid -D 000 600-.

–  Tighten new nut for output flange, specified torque → Item A -  36 mm socket for 3/4" drive –  Install bevel box → Chapter. –  Fill gear oil into bevel box → Chapter.