Sealing Ring In Drive Pinion, Replacing

Sealing ring in drive pinion, replacing, 01V, 5 SPD. A/T (AWD)
^ Observe general repair notes.

Special tools, testers and auxiliary items required

Thrust piece 3403:

^ 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.





^ Remove intermediate pinion - 2 - for front final drive from transfer housing.
^ Pull drive pinion - 3 - from output shaft.

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

Output pinion - 1 - remains on the drive pinion.

^ Drive out sealing ring using drift

Installing
Installation is performed in the reverse order of removal. Pay attention to the following:
^ 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 onto thrust piece 3403.
^ Drive seal in using thrust piece 3403 up to thrust piece stop.

Contact surface - A - of thrust piece must lie against drive pinion - B





^ Completely cover splines on end of shaft - arrow - using insulating tape without creasing or overlapping the tape, to prevent damage to seal when sliding on drive pinion.
^ Place drive pinion on center of output shaft. Installation position:

If drive pinion is installed carelessly, the sealing lips of the sealing ring can be damaged.





^ Slide drive pinion - 3 - together with the intermediate pinion - 2 - into final drive housing up to stop (tapered roller bearing).

Observe installation position of spur gears (pinions):

Gear identification - arrows - point outward, away from transmission.

^ Install intermediate flange for front final drive.
^ Install transfer case.