Get FinalDriveandDifferential -> 3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box Removed) Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Coat the outer circumference of the new seal with transmis‐

sion fluid.

– Fill the space between the sealing/dust lip -arrow- halfway with

Sealing Grease - G 052 128 A1- .

– Drive the gasket all the way in using the Seal Installer - Bevel

Box - T10298- . Do not tilt it while doing so.

– Install the bevel box. Refer to

⇒ “9 Bevel Box, Removing and Installing”, page 193 .

– Check the gear oil in the bevel box. Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218 .

– Check transmission fluid level inside the manual transmission.

Refer to ⇒ “8 Transmission Fluid, Checking”, page 192 .

3.3

Bevel Box Output Flange Seal, Replac‐

ing (Bevel Box Removed)

Special tools and workshop equipment required

♦ Holding Fixture - VW313-

♦ Press Piece - 42mm - VW516-

♦ Press Piece - Multiple Use - 40-105-

♦ Seal Installer - Flange Shaft - T10049-

♦ Gearbox Support - T10108-

♦ Counter Holder - T10108/1-

♦ Puller - Taper Roller Bearing - VAG1582- with a short sleeve

♦ Seal is located in the pinion housing. Refer to

⇒ Fig. ““Output Flange Seal in Pinion Housing, Removing and

Installing”“ , page 384 . Puller - Taper Roller Bearing - Adapter

6 - VAG1582/6- or Puller - Taper Roller Bearing - Adapter 6A

- VAG1582/6A-

♦ -1- Puller - Kukko 2-Arm - 70-180mm - 20/10-

♦ Seal is located on the output flange. Refer to

⇒ Fig. ““Output Flange Seal -arrow- Removing and Instal‐

ling:”“ , page 385 . Puller - Taper Roller Bearing - Adapter 13

- VAG1582/13-

♦ Continuation for All

♦ Torque Wrench 1601 - VAG1601-

♦ Three-Arm Puller - 45–2-

♦ The seal is located on the output flange

⇒ Fig. ““Output Flange Seal -arrow- Removing and Instal‐

ling:”“ , page 385

♦ Press Piece - Multiple Use - VW412-

3. Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box

381

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Press Piece - Multiple Use - VW454-

♦ Press Piece - Multiple Use - VW455-

♦ Press Plate - VW401-

♦ Two M8 x 30 mm stud bolts or Guide Pins - M8 - T10273-

♦ Removal Device Pin 2 - VW460/2-

♦ Sealing Grease - G 052 128 A1-

♦ Locking Compound - D 000 600-

♦ Only for seal in pinion housing. Refer to

⇒ Fig. ““Output Flange Seal in Pinion Housing, Removing and

Installing”“ , page 384

♦ Slide Hammer Set - VW771-

♦ Only for seal in pinion housing. Refer to

⇒ Fig. ““Output Flange Seal in Pinion Housing, Removing and

Installing”“ , page 384

♦ Slide Hammer Set - Hook - VW771/37-

♦ Two M 10 x 30 bolts

♦ Four M 12 x 10 nuts

Note

♦ Bevel box output flange seal can only be replaced with bevel

box removed.

♦ Inner race/tapered roller bearing is located in the output flange

bevel box.

♦ This is removed later in the procedure.

♦ Do not replace the tapered roller bearing for the output flange

bevel box and the shim!

– Remove the bevel box. Refer to

⇒ “9 Bevel Box, Removing and Installing”, page 193 .

– Mount the bevel box on the hole marked with the number -4-

-arrow- in the Gearbox Support - T10108- .

A - Insert the M 12 x 10 nut (quantity: 4) between bevel box and

Transmission Holder .

– Then align bevel box to the remaining three holes and secure.

– Place a drip tray underneath.

– Drain the gear oil out of the bevel box.

– Install two M 10 x 30 bolts -arrows- to stop the output flange

for the bevel box with the Gearbox Support - Stop Plate -

T10108/1- .

382

Rep. Gr.39 - Final Drive and Differential

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Unscrew Hex Nut for Output Flange.

A - 36 mm Socket for 3/4 Inch Drive

– Pivot the bevel box so that the output flange faces upward.

– Remove the output flange and the inner race/tapered roller

bearing from the bevel box shaft bevel gear.

A - Puller Three-Arm , for example Three-Arm Puller - 45-2-

– Please note the different installation locations for the output

flange seals:

The Output Flange Seal -arrow- is Inside the Pinion Housing.

Output flange seal in pinion housing, removing and installing. Re‐

fer to

⇒ Fig. ““Output Flange Seal in Pinion Housing, Removing and

Installing”“ , page 384 .

The Seal -arrow- is Located on the Output Flange.

Output flange seal, removing and installing. Refer to

⇒ Fig. ““Output Flange Seal -arrow- Removing and Installing:”“ ,

page 385 .

3. Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box

383

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Output Flange Seal in Pinion Housing, Removing and Installing

Seal, Removing

– Remove output shaft seal -A-.

•

The inner race/tapered roller bearing must be removed from

the output flange:

– Place the Press Piece - Multiple Use - 40-105- on the output

flange.

– Remove the inner race/tapered roller bearing from output

flange with the Tapered Roller Bearing Puller - VAG1582- .

Note

Instead of the Puller - Taper Roller Bearing - Adapter 6 -

VAG1582/6- , the Puller - Taper Roller Bearing - Adapter 6A -

VAG1582/6A- can be used.

Install Seal and Output Flange

– Cover pinion housing with a lint-free cloth.

– Clean any remaining locking fluid from the thread on the shaft

bevel gear.

•

If the shim -2- is removed during the removal of the output

flange, place it back in the pinion housing.

•

This will maintain the bearing pre-load on the shaft bevel gear

-1- inside the pinion housing.

– Insert the previous inner race/tapered roller bearing -3- in the

outer race/tapered roller bearing into the bevel box.

– Lightly lubricate the outer circumference of the new output

flange sealing ring -4-.

– Drive in the new seal using Seal Installer - Flange Shaft -

T10049- .

•

The seal must be flush with the upper edge of the housing.

– Fill the space between the sealing/dust lip halfway with Seal‐

ing Grease - G 052 128 A1- .

384

Rep. Gr.39 - Final Drive and Differential

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the output flange using the Two-Arm Puller -A-.

A - Two-Arm Puller , for example Puller - Kukko 2-Arm -

70-180mm - 20/10-

Note the following:

•

Do not use a damaged extractor hook.

The output flange may not be on edge when pulling out the

shaft bevel gear.

•

Mount the hooks on the bottom of the pinion housing.

Tension the removal hook with the Two-Arm Puller -arrows-.

Do not bend the removal hook toward the outside.

Interrupt the procedure if necessary, remove the output flange

again and repeat the process.

Output Flange Seal -arrow- Removing and Installing:

Seal, Removing

•

When removing the output flange seal, the inner race/tapered

roller bearing must also be removed.

– Place the Press Piece - Multiple Use - 40-105- on the output

flange.

– Remove the inner race/tapered roller bearing from output

flange with the Tapered Roller Bearing Puller .

– Remove the output flange seal.

Seal, Installing

•

First remove the pinion housing -1- along with the shaft bevel

gear -2- in order to install the seal:

– Remove the bolts for the pinion housing -1-; and carefully re‐

move the pinion housing diagonally of the protruding edges.

– Remove the pinion housing and the shaft bevel gear -2-.

– Clean the thread on the shaft bevel gear.

•

If the shim -3- was also removed during the removal of the

output flange, it must be placed back in the pinion housing.

•

This will maintain the bearing pre-load on the shaft bevel gears

inside the pinion housing.

3. Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box

385

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Place the old inner race/tapered roller bearing -1- into the pin‐

ion housing.

– Lightly lubricate the outer diameter of the new output flange

seal -2-.

– Drive in the new seal using Seal Installer - Flange Shaft -

T10049- .

•

The seal must be flush with the upper edge of the housing.

– Fill the space between the sealing and dust lip of the seal half‐

way with Sealing Grease - G 052 128 A1- .

– Press in the output flange along with the pinion housing and

shaft bevel gear all the way.

•

The shoulder -arrow- of the Press Piece - Multiple Use -

VW455- points to the shaft bevel gear.

– Install the M 8 X 30 mm stud bolts = -A- or Guide Pins - M8 -

T10273- into the axle drive housing.

– Slide a new O-Ring -1- onto the pinion housing -2-.

The pinion housing -2- and shim -3- only fit in one position.

– Install the previous shim -3-.

– Carefully install the pinion housing diagonally all the way with

Removal Device - Pin 2 - VW460/2- .

There is very little space between the pinion housing and the

bevel box housing.

The gap is closed when the pinion housing is tightened.

– Tighten the bolts for the pinion housing -2- diagonally.

Tightening Specification -item 21- ⇒ Item 21 (page 379) .

Continuation for All

386

Rep. Gr.39 - Final Drive and Differential

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Coat Threads of the New Hex Head Nut with Locking Compound

- D 000 600- .

– Tighten new output flange hex head nut.

Tightening Specification -item 15- ⇒ Item 15 (page 378) .

A - 36 mm Socket for 3/4 Inch Drive

– Install the bevel box. Refer to

⇒ “9 Bevel Box, Removing and Installing”, page 193 .

– Check the gear oil in the bevel box. Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218 .

3.4

Output Flange, Replacing and Selecting

New Shim for Output Flange, Bevel Box

Removed

– Remove the output flange and, if necessary, remove the inner

race/tapered roller bearing from the output flange. Refer to

⇒ “3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box

Removed)”, page 381 .

This adjustment is necessary whenever the output flange is being

replaced. This creates the preload on the tapered roller bearing

for the shaft bevel gear.

– Measure the length of the shaft on the old and new output

flange to get the difference.

Example:

Old output flange

New output flange

Difference

42.90 mm

43.00 mm

0.10 mm

If the new output flange is longer- install a thinner shim.

If the previously mentioned output flange is longer- install a thicker

shim.

Allocation. Refer to the Parts Catalog.

– Install the output flange. Refer to

⇒ “3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box

Removed)”, page 381 .

3.5

Needle Bearing (polygon bearing) on Right Flange Shaft and Seal on Right

Flange Shaft, Replacing

3. Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box

387

FinalDriveandDifferential -> 3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box Removed) for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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