Differential Shaft Seal

Differential Shaft Seal

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Socket (T10023)

• Thrust pad (T40107)

• Assembly lever

• Cleaning solution (D 009 401 04)

Removing

• The differential shaft seal can be replaced with transmission installed.

- Drain ATF => [ ATF, Draining for ATF Flush ] ATF, Draining for ATF Flush.

- Remove differential => [ Differential ]

- Remove right flange shaft.

• In the case of insufficient accessibility in the vehicle, right flange shaft must not be completely removed. In that case, it only needs to be pulled out of transmission housing a little in order to create enough room to remove and install shaft seal.

CAUTION!
• In the following procedures, the differential shaft surface must not come in contact with hard objects. Even small scratches or damage to the differential shaft sealing surface cause lack of seal and the transmission must be replaced completely.

- Place a punch on a side hole of pinion shaft seal and punch a small hole - arrow - to install a metal screw in shaft seal.





- Install metal screw with large head in shaft seal hole.





- Use a stable lever - 1 - with center notch - arrow - to install metal screw.





- Position lever on metal screw.

CAUTION!
Lay an appropriate wood or plastic plate - 2 - between lever and transmission housing to prevent damage.

• The housing must not be damaged.

- Remove shaft seal.

Installing

- Check differential shaft for wear => [ Differential Shaft, Checking for Wear ].

- Clean breather tube - arrow - using pressurized air and lay a cloth on interior side of breather tube.





- Clean differential shaft sealing surface - arrow - with cleaning solution (D 009 401 04) and a soft cloth; turn differential shaft to do so.





• Selector shaft lever must not be in position "P".

- Remove stubborn deposits with the fingernail - do not use tools at all.

CAUTION!
• Do not clean the differential shaft mechanically with tools or polishing paste under any circumstances. Even small scratches or damage to the differential shaft sealing surface cause lack of seal and the transmission must be replaced completely.

- Coat outside circumference of shaft seal with ATF.

- Check assembly aid (T40107/2) for cracks or burrs. Do not use a damaged assembly aid.

- Place assembly aid (T40107/2) on pressure sleeve (T40107/1) and slide shaft seal - 1 - onto pressure sleeve.





• Closed side of shaft seal points towards tool.

- Remove assembly aid (T40107/2).

- Connect pressure sleeve (T40107/1) with shaft seal - 1 - to differential shaft.

- Place selector shaft lever in "P" position (all the way back).





- Rotate nuts on spindle (T40107/3) all the way back.

- Rotate spindle (T40107/3) to stop with open-end wrench.

• This installs spindle securely on differential shaft.

- Bring pressure sleeve (T40107/1) into correct position.

• Tabs - arrows - pressure sleeve circumference must engage in notches on transmission housing.

- Press shaft seal into transmission housing with pressure sleeve and tighten nut to 17 Nm using Torque wrench (V.A.G 1331 ) and Socket (T10023).





• Shaft seal must settle for 2 minutes.

- After waiting 2 minutes, remove nut and remove pressure sleeve in driving direction.

- Check whether shaft seal lip visible from outside lies on cylindrical differential shaft sealing surface and not on chamfer - arrow -; press shaft seal on, if necessary





- Install right flange shaft.

- Install differential housing and front final drive cover => [ Differential ].

• With transmission removed:

• In order to be able to perform a test drive, the transmission must be installed in the vehicle to check for leaks.

- Fill with ATF => [ ATF, Filling for ATF Flush ] ATF, Filling for ATF Flush.

- Perform an extended test drive and finally check for leaks on bleeder hole - arrow A - on front final drive cover.





• The bleeder hole is covered with a protective plate in certain transmissions.

• On new front final drive covers, the ventilation opening has been relocated to the lowest bolt - arrow - (inner oil canal); a leak is visible only from underneath on the front final drive cover.

• If oil escapes at the bleeder hole, repair must be repeated.