Audi Workshop Service and Repair Manuals

Renewing oil seal and grooved ball bearing for flange for propshaft on gearbox

Special tools and workshop equipment required

t	Adapter -VW 295 A-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Tube -VW 415 A-

t	Tube -VW 416 B-

t	Press tool -VW 433-

t	Press tool - VW 454-

t	Oil seal extractor lever -VW 681-

t	Multi-purpose tool -VW 771-

t	Punch -2005-

t	Torque wrench -V.A.G 1331-

t	Shim -016 311 391 B-

t  Counterhold tool -T10172- with adapter -T10172/5-

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

Exploded view

1 -

Gearbox

2 -	Grooved ball bearing

3 -	Bearing housing

q	With damper weight (depending on version)

4 -

Oil seal

q	Driving in → Anchor

5 -	Flange shaft

q	On vehicles with 4-cyl. TDI engine and vibration damper → Anchor

6 -	Bolt, 25 Nm

q

6x

7 -

O-ring

q

Renew

8 -

Circlip

9 -	Dished spring

q	Mark installation position when removing: larger diameter (concave side) towards shims → Item

10 -

Shims

11 -

Spring

12 -	Oil drain plug, 40 Nm

Removing l  Gearbox in vehicle   Note

The flexible joint (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged. –  Disconnect exhaust system at clamps -arrows-.   Note Illustration shows vehicle with V6 petrol engine. –  Disengage rear section of exhaust system at rubber mountings and remove.   Note A second mechanic is required for removing the rear section of the exhaust system.

–  Unbolt heat shield for propshaft -arrows-.

–  Unbolt propshaft from gearbox. –  Slide propshaft together towards rear final drive. The constant velocity joints can be moved axially.

–  Use wire -arrow- to tie propshaft -1- onto heat shield.

Vehicles with 4-cylinder TDI engine: –  Lever off vibration damper -A- (weight approx. 5 kg) by applying a lever -B- on alternate sides. Continued for all vehicles: –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Remove rear oil drain plug (on end cover) and allow gear oil to drain off. –  Unscrew bolts securing bearing housing.   Note Bearing housing is pressed slightly off end cover by coil spring when securing bolts are loosened.

If the bearing housing is not pressed off: –  Pull flange shaft off end cover together with bearing housing and damper weight. –  Detach bearing housing.

–  Detach circlip from flange shaft. –  Press out flange shaft.

–  Pull out flange shaft oil seal. –  Thoroughly clean seat for oil seal.

–  Press out grooved ball bearing.

Installing –  Press in new grooved ball bearing into bearing housing.

–  Preparing oil seal for installation: A -  Shim -016 311 391 B- (1.7 mm thick) B -  Oil seal –  Lightly oil outer circumference of seal -B-. –  First fit shim -016 311 391 B-, then oil seal onto punch -2005-. l  Installation position: open side of seal towards gearbox.

–  Drive in flange shaft oil seal. –  Remove shim after driving in oil seal. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.

–  Press in flange shaft. –  Fit circlip onto flange shaft. –  Lightly oil O-ring and fit into groove on bearing housing. –  Fit dished spring and shims into bearing housing. l  Installation position: larger diameter (concave side) towards the shims. –  Fit coil spring onto flange shaft. –  Then tighten bearing housing bolts alternately in diagonal sequence. –  Secure propshaft to gearbox → Rear final drive 01R; Rep. Gr.39. –  Fill manual gearbox with gear oil and check oil level → Chapter.