Front Final Drive Sealing Ring/Transmission Housing, Replacing

Front final drive sealing ring/transmission housing, replacing, 01V, 5 SPD. A/T (AWD)

^ Observe general repair notes.

Special tools, testers and auxiliary items required:

^ Extractor lever VW681
^ Double sealing ring installer 3383
^ Torque wrench 40-200NM V.A.G. 1332
^ Engine-/gearbox jack V.A.G 1383 A with universal transmission support V.A.G1359/2
^ Oil extraction device V.A.G. 1358A

A faulty sealing ring lets ATF or axle oil escape into the converter housing via the center vent of the seal (between the two sealing lips).

Furthermore, a faulty sealing ring can leak ATF into the differential. It over-fills and oil escapes at the front final drive vent.

Removing
^ Raise vehicle.
^ Remove wheel.

Vehicles with TDI engine





^ Remove noise insulation for right drive axle from wheel housing - arrows -.

All vehicles
^ Remove right front exhaust pipe.





^ Remove shielding plate/drive axle - arrows - on right side. The third bolt is not visible in the illustration.

Continued for all vehicles
^ Remove right drive axle - 1 -.





^ Unscrew sealing plug for checking transmission fluid - arrow - and extract 0.5 L axle oil from front final drive using oil extraction unit V.A.G. 1358A.

Axle oil must always be extracted from front final drive because axle oil will be mixed with ATF otherwise.





^ Remove bolt for flanged shaft - arrow - and secure against turning using a drift.
^ Place drip tray V.A.G. 1306 underneath.
^ Pull out right flanged shaft.
^ Remove right transmission support.
^ Unscrew bolts for front final drive cover and remove cover.
^ Pull out differential and remove.





^ Remove tapered roller bearing outer race for differential - 1 - and shim - 2 - which is behind it from transmission housing by hand.

Shim - 2 - is pre-determined and must not be exchanged for a shim with another thickness.

^ Remove left flanged shaft.





^ Pull out sealing ring.

Extractor lever must be positioned behind both sealing lips of the sealing ring. Do not position at outer circumference of sealing ring, otherwise the contact surface in transmission housing will be damaged. Guide the lever carefully when prying the seal.

Installing
^ Examine oil seal seat in transmission housing for damage; if necessary rework.
^ Coat outer circumference and sealing lips of sealing ring with axle oil.





^ Slide seal onto double sealing ring installer 3383 so that the projecting sealing lip of sealing ring faces tool.





^ Drive in new oil seal up to stop.





^ Insert adjustment shim - 2 - and tapered roller bearing outer race for differential - 1 - into transmission housing up to stop by hand.
^ Insert differential into transmission housing.





^ Replace O-ring - arrow -.





^ Install cover for front final drive.

Tightening sequence:
^ Step 1: Tighten bolts - 1 -, - 2 - and - 3 - by hand.
^ Install right transmission support.
^ Install left flanged shaft.
^ Install right flanged shaft.





^ Screw in bolt for flanged shaft - arrow - and secure against turning using a drift.
^ Check axle oil in front final drive with transmission installed.





^ Install right drive axle - 1 -.

All vehicles
^ Install shielding plate/drive axle -arrows- on right side. The third bolt is not visible in the illustration.
^ Install right front exhaust pipe.

Vehicles with TDI engine





^ Install noise insulation - arrows - for right drive axle to wheel housing.

Continued for all vehicles
^ Install wheel.