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  Bolts M10 x 30 (Qty. 2) 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 ► and Passat 2006 ► with V6 engine → Chapter    Golf 2009 ► with 2.0 l 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 output flange for bevel box with stop plate -T10108/1-. Use M10 x 30 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. This must be pull off subsequently → 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 1582/6- may be used in place of grip -V.A.G 1582/6A-.

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

l  The 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-.

–  Press 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. –  Coat thread of new hexagon nut with locking fluid -D 000 600-.

–  Tighten new nut for output flange. Torque setting: → Item. A -  36 mm socket for 3/4" drive –  Install bevel box:    Golf 2004 ► and Passat 2006 ► with V6 engine → Chapter    Golf 2009 ► with 2.0 l engine → Chapter –  Fill gear oil into bevel box → Chapter.