Seal In Front Final Drive Intermediate Flange, Replacing

Seal in front final drive intermediate flange, replacing, 01V, 5 SPD. A/T (AWD)
^ Observe general repair notes.

Special tools, testers and auxiliary items required

Torque wrench 550 Nm V.A.G. 1331:

Engine-/gearbox jack V.A.G 1383 A with universal transmission support V.A.G1 359/2:

Removing
^ Remove transfer case.





^ Remove bolts - arrows - at intermediate flange for front final drive.
^ Alignment pin - A - and magnet - B - remain in intermediate flange.

Slowly and carefully remove intermediate flange for front final drive from transmission housing. The spur gears (pinion) can otherwise fall out of the transmission.

Spur gears which have fallen to the floor may no longer be installed. The transmission must be replaced.

^ Lift off intermediate flange for front final drive.





^ Do not remove output pinion - 1 -, intermediate pinion - 2 - and drive pinion - 3 - for front final drive and secure against falling out.

If spur gears (pinion) for front final drive have been removed anyway, gear identification for output pinion - 1 - and intermediate pinion - 2 - must point outward (away from transmission) - arrows - for re-installation.

Installing
Installation is performed in the reverse order of removal. Pay attention to the following:





^ Make sure alignment bushing - A - is correctly seated before installing.
^ Insert new seal - B -.
^ Install intermediate flange for front final drive.

When installing the intermediate flange to the output shaft carelessly, the sealing lip of the sealing ring - arrow - can be damaged.





^ Screw in bolts - arrows - on intermediate flange for front final drive hand-tight.
^ Make sure that alignment pin - A - and magnet - B - are seated correctly.
^ Install transfer case.





^ Screw in bolts - A - and - C - for transfer case - 2 - hand4ight.
^ Tighten bolts - B - for intermediate flange/front final drive - 1 - and bolts - A - for transfer case - 2 - in stages in diagonal sequence to tightening torque.
^ Tighten bolts - C - for transfer case at intermediate flange to tightening torque.
^ Fill transfer case with axle oil and check oil level.
^ Top off ATF and check ATF level.

Special tools, testers and auxiliary items required

Thrust piece 3404:

^ Sealing grease G052128A1





An inspection opening is provided on the left side of the intermediate flange - arrow - to check for oil leaks for the sealing ring in drive pinion and the sealing ring in intermediate flange.

Removing
^ Remove transfer case.
^ Remove intermediate flange for front final drive.
^ Drive out seal in direction of transfer case using a drift.

Installing
Installation is performed in the reverse order of removal. Pay attention to the following:
^ Check sealing ring seat in intermediate flange for damage; rework if necessary.
^ Coat outer circumference and sealing lips of sealing ring with axle oil.
^ Fill area between sealing lip and dust lip halfway with sealing grease G052128A1.





^ Slide seal with open side - arrow - onto thrust piece 3404.
^ Drive in seal up to stop using thrust piece 3404.
^ Install intermediate flange for front final drive.
^ Install transfer case.