Seal For Output Flange/Bevel Gear Transfer Case, Replacing
Seal for output flange/bevel gear transfer case, replacing, 02M/02Y, 5 & 6 Speed M/T, AWD
Special tools, testers and auxiliary items required
^ Holding fixture VW 313
^ Tube 42 mm dia. VW 516
^ Thrust piece V.A.G 40-105
^ Thrust piece T10049
^ Transmission holder T10108
^ Stop plate T10108/1
Special tools, testers and auxiliary items required
^ Taper roller bearing puller V.A.G 1582
^ Attachment V.A.G 1582/6A
^ Torque wrench V.A.G 1601
^ Two arm puller Kukko 20/10
^ Three arm puller Kukko 45-2
^ Locking fluid
Work procedure
- Remove bevel gear transfer case.
- Set bevel gear transfer case on hole - arrow - designated with the number - 4 - in transmission holder.
- Then align bevel gear transfer case to the remaining 3 holes and secure.
A - M12x10 nut (4x)
- Secure output flange for bevel gear transfer case using stop plate T10108/1.
- Remove hex bolt for output flange.
A - Wrench socket insert 3/4 drive
- Pull out output flange with seal and bearing inner race.
A - Three arm puller Kukko 45-2
- Place thrust pad V.A.G 40-105 on output flange.
- Pull off bearing inner race from output flange using Taper roller bearing puller V.A.G 1582.
- Remove sealing ring from output flange.
- Clean locking fluid residue from threads on shaft bevel gear.
- Swing bevel gear transfer case so that drive pinion housing - 1 - points upward.
- Insert small inner race for tapered roller bearing of shaft bevel gear.
- Drive in new sealing ring for output flange to stop using thrust piece T10049.
- Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.
- Grease splines of output flange and on shaft bevel gear evenly with multi-purpose grease.
- Pull in output flange.
A - Two arm puller Kukko 20/10
- Position pulling hook on underside of drive pinion housing.
- Coat threads of hex bolt and shaft bevel gear with locking compound.
- Tighten new hex nut for output flange to 45 Nm.
A - Wrench socket insert 3/4 drive
- Install bevel gear transfer case.
- Check gear oil in manual transmission with bevel gear transfer case.