Audi Workshop Service and Repair Manuals

Renewing needle bearings (polygon bearings) for flange shaft (right-side) with bevel box installed

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	Assembly tool -VAS 3253-

t	Tensioning tool -T10047-

t  Hexagon key -V.A.G 1669-

t  Used oil collection and extraction unit -V.A.G 1782-

t  Puller -T10037-

Procedure –  Remove centre noise insulation -arrows-.

–  Remove noise insulation (right-side) -arrows-.

–  Unscrew nut -arrow- for coupling rod on anti-roll bar (right-side).

–  Unscrew nut (top) from swivel joint (right-side). –  Position ball joint puller -3287 A- as shown in illustration and pull off swivel joint.   Note To protect thread, leave nut screwed several turns onto ball joint. –  Turn steering wheel to the left.

–  Unscrew heat shield for drive shaft on right of bevel box -arrows-. –  Unbolt drive shaft (right side) from gearbox flange shaft. –  Lift drive shaft (right-side) up and secure with wire.

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Unscrew oil return line for turbocharger from engine oil sump and cylinder block -arrows 1 and 2-. –  Unscrew countersunk bolt for flange shaft (right-side) -arrow 1- using hexagon key -V.A.G 1669-.

–  Bolt puller -T10037- to flange shaft (right-side). –  Use knurled nut -T10037/1- and lower support -A- to align puller parallel with flange. –  Pull out flange shaft.

–  Fit tensioning tool -T10047- so that markings “B” on both sections of tensioning tool point towards each other. l  The stepped shoulders -arrows- must then be below the bearing. –  Screw both sections together as far as stop.

–  Remove circlip -A- securing bearings. –  Rotate shaft when pressing off -arrow- to prevent contact surface of bearings on shaft from being damaged.

–  Rotate shaft when pressing on -arrow- to prevent contact surface of bearings on shaft from being damaged. –  Secure bearings with a new circlip. –  Carefully drive in flange shaft (turn flange shaft when doing so). –  Secure flange shaft with countersunk bolt. –  Install oil return line from turbocharger with new seal → Rep. Gr.21. –  Bolt drive shaft (right-side) to gearbox flange shaft → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Install heat shield for drive shaft (right-side) -arrows-. –  Install swivel joint and coupling rod → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Check gear oil in manual gearbox with bevel box → Chapter. –  Install noise insulation panels → General body repairs, exterior; Rep. Gr.50. –  Fill up with engine oil → Rep. Gr.17. Tightening torques

Component	Nm
Flange shaft to gearbox (countersunk bolt)	25
Heat shield for drive shaft to bevel box	25