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	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/6- or 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  Sealing grease -G 052 128 A1- t  2 Bolts M 10 x 30 t  4 Nuts M 12 x 10 Removing   Note The oil seal for the bevel box and output flange can be renewed only with the bevel box removed. Vehicles with turbo diesel engine without particle filter and vehicles with 6-cylinder petrol engine –  Remove bevel box → Chapter. Vehicles with turbo diesel engine with particle filter –  Remove bevel box → Chapter.

–  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-. –  Remove output flange hexagon nut. 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 When output flange is pulled off, inner race of tapered roller bearing remains on output flange and must also be pulled off → Anchor. –  Seat thrust pad -40-105- on output shaft.

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

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

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 grease -G 052 128 A1-.

–  Pull in output flange using two arm puller-A-. A -  Two arm puller, e.g. -Kukko 20/10- –  Apply puller hooks to lower side of pinion housing. –  Coat thread of new hexagon nut with locking fluid D 000 600. –  Tighten new nut for output flange.

Torque setting: 480 Nm A -  36 mm socket for 3/4" drive Vehicles with turbo diesel engine without particle filter and vehicles with 6-cylinder petrol engine –  Install bevel box → Chapter. Vehicles with turbo diesel engine with particle filter –  Install bevel box → Chapter. –  Check gear oil in bevel box → Chapter.