Pinion Seal Coupling (AOC), Replacing

Pinion seal coupling (AOC), replacing
Special tools: 999 5069, 999 5652, 999 5893, 999 7025, 999 7058

Note: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.

Removal
Removing the exhaust system and the propeller shaft
Remove the exhaust system and the propeller shaft.

Removing the flange





Remove the nut for the flange. Use counterhold 999 5652 and adapter 999 7058. Mark the flange in relation to the end of the shaft.
Position a container underneath the Active On-demand Coupling.





Remove the flange. If the flange is stuck, use puller 999 5893.

Note: For cars with a vibration damper on the Active On-demand Coupling flange. Use 55 mm long screws for the puller. The oil pump may be damaged if too long screws are used.





Check that the mating surface on the flange is not damaged. If necessary replace the flange.

Removing the seal
Remove the seal from the Active On-demand Coupling. Use extractor 999 5069.





Check thoroughly that no seal residue remains.

Installation
Installing the seal





Lubricate the new seal using oil for the Active On-demand Coupling, P/N 116 1641 (1 liter pack). Use drift 999 7025 for installation. Tap the seal into place until the surface of the drift is against the housing for Active On-demand Coupling.

Installing the flange





Install the flange on the AOC (Active On-demand Coupling) using the previous markings (if using the old flange).
Install a new nut for the shaft and flange. Use counterhold 999 5652 with adapter 999 7058. Tighten the nut. Fill the AOC (Active On-demand Coupling) with oil. Check the oil level.

Installing the propeller shaft and the exhaust system
Install the propeller shaft and the exhaust system.