Front Flange Shaft and Driveshaft Seal, Transfer Case

Front Flange Shaft and Driveshaft Seal, Transfer Case

Special tools, testers and auxiliary items required

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Oil Collecting and Extracting Device (V.A.G 1782)

• Puller (VW 391)

• Puller (T10055) with adapter (T10055/2)

• Counterhold Tool Touareg V10 (T10172) and Adapter (T10172/6)

• Transmission Support (T10337)

• Inductive Heater (VAS 6414)

• Thrust Piece (T10380)

• Thrust Piece (T10449)

• Sealing grease (G 052 128 A1)

Removing

- For vehicles equipped with air suspension, activate the vehicle lift mode.

- Raise the vehicle.

- Remove the bolts and the noise insulation - 2 -.






- Place the (V.A.G 1782) underneath the transfer case.

- Remove the oil drain plug - 2 - and drain the transmission fluid.






- Put the oil drain plug back in - 2 - using some locking fluid (AMV 185 101 A1). Tightening specification => [ Tightening Specification ] Gear Oil Level In the Transfer Case, Checking.

- Set the (V.A.G 1383 A) using the (T10337) underneath the transfer case.






- Use the (V.A.G 1383 A) to raise the transfer case a little bit.

Risk of Accident.

• Do not walk away from the (V.A.G 1383 A) during assembly and do not let it remain under the vehicle without someone in attendance.

- Remove bolts - 1, 2 - for the transmission support.






- Remove bolts - 1, 2 - and remove the bracket from the transfer case.






• Ignore the bolts - arrows -.

- Remove the bolts - arrows - from the connection between the front driveshaft and the transfer case.






- Use a (T10172) to counterhold the adapters (T10172/6).

- Secure the front driveshaft to the body so it is up and out of the way.

- Lower the transfer case slightly.

- Remove the locking ring - 1 -.






- Tighten the (VW 391) on the flange shaft.






A M8x35 bolts
B M8 nuts

- Lower the flange shaft.

- Use a needle-bearing drift to punch a hole in the center of the shaft seal.






- Install the 4 mm diameter screw - arrow -.

• Do not damage the sealing surface on the output shaft.

• Do not screw the screw in too tight or you will damage the bearing that is behind it.

- Use the (T10055) to remove the shaft seal.






Installing

Install in reverse order of removal. Note the following:

- Apply a light layer of lubricant on the outer circumference of the shaft seal.

- Fill the space between the sealing and dust lips halfway with sealing grease (G 052 128 A1).

- Install the new shaft seal all the way without tilting it.






- Use the (VAS 6414) to heat the flange shaft - 1 - to approximately 80 °C (176 °F) and drive it on using the (T10380).






- Set the locking ring in place - 1 -.






- Install the front driveshaft on the transfer case. Refer to => [ Front Driveshaft ] Front Driveshaft.






• Replace the driveshaft bolt (self-locking).

- Install the transmission support. Refer to => [ Transmission Support and Bracket ] Transmission Support and Bracket.

- Top off the transmission fluid and check the fluid level in the transfer case. Refer to => [ Gear Oil Level in the Transfer Case, Checking ] Gear Oil Level In the Transfer Case, Checking.

- Deactivate the vehicle lift mode using a vehicle with air suspension.