Volkswagen Workshop Service and Repair Manuals

Renewing bevel box output flange oil seal (bevel box removed)

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	Taper roller bearing puller -V.A.G 1582- with short sleeve

t	Only for seal in pinion housing → Fig.

t	Adapter -V.A.G 1582/6- or Adapter -V.A.G 1582/6A-

t	-1-Two arm puller -Kukko 20/10-

t	Only for seal on output flange → Fig.

t	Adapter -V.A.G 1582/13-

t	Continuation for all

t	Torque wrench -V.A.G 1601-

t	Three arm puller -Kukko 45-2-

t  Only for seal in pinion housing → Fig.

t  Multipurpose tool -VW 771-

t  Only for seal in pinion housing → Fig. t  Puller hooks -VW 771/37-

t	Only for seal on output flange → Fig.

t	Press tool -VW 412-

t	Thrust piece -VW 454-

t	Installing sleeve -VW 455-

t	Pressure plate -VW 401-

t	2 M 8 X 30 mm stud bolts or M8 guide bolts -T10273-

t	Pin -VW 460/2-

Continuation for all Sealing grease -G 052 128 A1- 2 Bolts M10 x 30 4 Nuts M12 x 10   Note t  The oil seal for the output flange of the bevel box can be renewed only with the bevel box removed. t  The bevel box output flange has an inner race/taper roller bearing. t  This is removed later in the process. t  The taper roller bearing for the bevel box output flange and the shims are not replaced! Vehicles with 6-cylinder petrol engine and vehicles with turbo diesel engine without particulate filter –  Remove bevel box → Chapter. Vehicles with turbo diesel engine with particulate filter up to approx. 10.09 –  Remove bevel box → Chapter. Vehicles with turbo diesel engine and particulate filter (Golf 2009 ► and CC from approx. 11.09, Passat 2011 ►) –  Remove bevel box → Chapter. Continuation for all

–  Set bevel box in gearbox support -T10108- on hole -arrow- marked with the number -4-. A -  Lay nuts M 12 x 10 (Qty. 4) between bevel box and gearbox support. –  Then align bevel box with remaining 3 holes and secure. –  Place drip tray underneath. –  Drain oil from bevel box. –  Lock bevel box output flange with stop plate -T10108/1-, screwing in M 10 x 30 bolts -arrows-.

Removing hexagon nut for output flange A -  36 mm socket for 3/4" drive

–  Swing bevel box so that output flange points upwards. –  Remove output flange together with inner race/taper roller bearing from shaft bevel gear of bevel box. A -  Three arm puller, e.g. -Kukko 45-2-

–  Please note different installation positions of seal for output flange: Output shaft seal -arrow- is located in pinion housing. Removing and installing output flange seal in pinion housing → Fig..

Seal -arrow- is located on output flange. Removing and installing output flange seal → Fig.

Removing and installing output flange seal in pinion housing:. Removing oil seal –  Pull out seal -A- for output flange.

l  Bearing inner race/taper roller bearing must be detached from output flange: –  Seat thrust pad -40-105- on output shaft. –  Pull inner tapered roller bearing race off output flange using tapered roller bearing puller.   Note Adapter -V.A.G 1582/6- may be used in place of adapter -V.A.G 1582/6A-.

Installing seal and output shaft –  Cover pinion housing with a lint-free cloth. –  Clean residual locking fluid from thread of shaft bevel gear. l  If shim -2- was also removed when output flange was removed, it has to be reinserted in pinion housing. l  It assures bearing preload of shaft bevel gear -1- in pinion housing. –  Place existing bearing inner race/tapered roller bearing -3- in outer race in bevel box. –  Lightly oil outer circumference of new seal -4- for output flange.

–  Drive in new oil seal with thrust piece -T10049-. l  Seal must be flush with upper edge of housing. –  Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1-.

–  Pull in output flange using two arm puller-A-. A -  Two arm puller, e.g. -Kukko 20/10- Please note the following: l  Use new or nearly new puller hooks! l  The output flange must not be canted. l  Fit puller hooks as far as they will go onto underside of pinion housing. l  Take up slack on puller hooks fully with two arm puller-arrows-. l  Puller hooks should not bend outwards. l  If necessary, halt pulling process, pull off output flange again and restart pulling process.

Removing and installing output flange seal -arrow-: Removing oil seal

l  Bearing inner race/taper roller bearing must be removed in order to remove output flange seal: –  Seat thrust pad -40-105- on output shaft. –  Pull inner tapered roller bearing race off output flange using tapered roller bearing puller. –  Remove seal from output shaft.

Installing oil seal l  To install seal, pinion housing -1- with shaft bevel gear -2- first has to be removed: –  Unscrew securing bolts for pinion housing -1-; then carefully lever pinion housing off cross-wise at projecting edges. –  Remove pinion housing with shaft bevel gear -2-. –  Clean shaft bevel gear thread. l  If shim -3- was also removed when output flange was removed, it has to be reinserted in pinion housing. l  It assures bearing preload of shaft bevel gear in pinion housing.

–  Place existing bearing inner race/tapered roller bearing -1- in pinion housing. –  Lightly oil outer circumference of new seal -2- for output flange.

–  Drive in new oil seal with thrust piece -T10049-. l  Seal must be flush with upper edge of housing. –  Half-fill space between sealing lip and dust lip of seal with sealing grease -G 052 128 A1-.

–  Press output flange and pinion housing plus shaft bevel gear together as far as they will go. l  Shoulder -arrow- of installing sleeve -VW 455- faces shaft bevel gear.

–  Screw in M 8 X 30 mm stud bolts = -A- or M8 guide bolts -T10273- into final drive housing. –  Slide new O-ring -1- onto pinion housing -2-. Pinion housing -2- and shim -3- only fit in one position. –  Install existing shim -3-. –  Carefully drive in pinion housing cross-wise to stop using bolt -VW 460/2-. Narrow gap remains between pinion housing and housing for bevel box. Gap closes when pinion housing is screwed tight. –  Tighten securing bolts for pinion housing -2- cross-wise. Torque setting → Item Continuation for all

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 Vehicles with 6-cylinder petrol engine and vehicles with turbo diesel engine without particulate filter –  Install bevel box → Chapter. Vehicles with turbo diesel engine with particulate filter up to approx. 10.09 –  Install bevel box → Chapter. Vehicles with turbo diesel engine and particulate filter (Golf 2009 ► and CC from approx. 11.09, Passat 2011 ►) –  Install bevel box → Chapter. Continuation for all –  Check gear oil in bevel box → Chapter.