Output Shaft: Service and Repair

Flange Shaft Seal and Ball Bearing

Special tools, testers and auxiliary items required

• Pressure Plate (VW 401)

• Pressure Plate (VW 402)

• Punch (VW 412)

• Sleeve (VW 415 A)

• Seal Driver-Front Wheel Bearing (30 - 100)

• Sleeve (2040)

• Thrust Piece (T40165)

• Sealing Grease (G 052 128 A1)

Procedure

- Remove the center differential housing. Refer to => [ Center Differential Housing, Transmission Installed ] .

- Remove circlip - arrow -.





- Remove the flange shaft by positioning the center differential housing so that the flange shaft does not touch the pressure plates (VW 401) and (VW 402).





- Remove the flange shaft using a suitable drift.

- Pry out the shaft seal - 1 -.





• Disregard - 2 -.

- Installing the flange shaft ball bearing and spacer sleeve





- Installing the flange shaft ball bearing.

• The shoulder on the (VW 415 A) - arrow - faces toward the (VW 412).





- Then press the spacer sleeve => [ (Item 2) Spacer Sleeve ] in using the (VW 415 A).

- Lightly oil outer circumference of shaft seal and drive in as far as stop with (T40165).





• Installation position: Open side of shaft seal faces transmission.

- Fill area between sealing lip and dust lip halfway with Sealing Grease (G 052 128 A1).

- Press in flange shaft.





- Install the flange shaft into the center differential housing from underneath.

- Position the housing and flange shaft on the (VW 402) under the shop press.

- Install the inner bearing race with using the sleeve on the flange shaft.

- Install a new circlip - arrow - for the flange shaft.





- Install the center differential housing. Refer to => [ Center Differential Housing, Transmission Installed ] .