Get FinalDriveandDifferential -> 3.5 Needle Bearing (polygon bearing) on Right Flange Shaft... Replacing 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 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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Special tools and workshop

equipment required

♦ Press Plate - VW401-

♦ Press Plate - VW402-

♦ Press Piece - Rod -

VW407-

♦ Press Piece - Multiple Use

- VW412-

♦ Bearing Installer - Rear

Wheel Bearing Kit -

VAS3253-

♦ Bearing Installer - Needle

Bearing - T10047-

♦ Seal Installer - Crankshaft - VW204B-

388

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

♦ Press Piece - Bushing - VW434-

♦ Puller - Flanged Shaft - T10037-

♦ Socket And Extended Bit - T10107A-

3.5.1

Removing

The right driveshaft must be removed later in the procedure.

– With the vehicle still standing on its wheels, loosen the right

front collar bolt -arrow- a maximum 90°, otherwise the wheel

bearing will get damaged. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Remove the right front wheel.

– Remove the noise insulation under the engine/transmission, if

equipped. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise In‐

sulation .

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

389

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the driveshaft heat shield from the bevel box

-arrows-.

– Remove the right driveshaft. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

Vehicles with a Particulate Filter

– Remove the nuts -1 and 2- and then remove the particulate

filter bracket.

Continuation for All

– Place the drip tray under the transmission.

– Remove the right flange shaft bolt -arrow 1- with the Socket

And Extended Bit - T10107A- and install two bolts in the flange

and counterhold the flange shaft with the pry bar.

390

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

– Tighten the Puller - Flanged Shaft - T10037- on right flange

shaft.

Note

To remove right flange shaft, use Puller - Flanged Shaft - T10037-

to avoid damaging the bearing on flange shaft.

– Place a spacer (for example, Press Piece - Bushing - VW434- )

between the transmission support and the Stub Shaft coun‐

terhold Tool - Knurled Nut - T10371/1- .

– Align the Puller - Flanged Shaft - T10037- parallel to the flange

using the Spindle -A-.

– Install the right flange shaft.

Attach the Bearing Installer - Needle Bearing - T10047- , as

shown in the illustration, to the flange shaft.

•

The markings “B” on both parts face each other.

The depressions -arrows- must be under the bearing.

– Bolt the parts together all the way.

– Remove the locking ring -A- out of the needle bearing.

– So that the bearing contact surface on shaft is not damaged,

shaft must be rotated during the pressing procedure -arrow-.

– Remove the old seal -A- from the groove -arrow-.

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

391

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

6-Speed Manual Transmission 02Q - Edition 05.2013

3.5.2

Installing

– Coat the new seal -A- with transmission fluid and insert it into

the groove -arrow- of the flange shaft.

Note

Make sure seal is not tilted.

– Attach the Bearing Installer - Needle Bearing - T10047- to the

flange shaft. Refer to ⇒ page 391 .

– So that the bearing contact surface on shaft is not damaged,

shaft must be rotated during the pressing procedure -arrow-.

– Secure the needle bearing with a new circlip.

– Carefully install the flange shaft while rotating it at the same

time.

– Install flange shaft with a screw and tighten to tightening spec‐

ification ⇒ Item 13 (page 401) .

Install in reverse order of removal.

Vehicles with a Particulate Filter

– Install the particulate filter bracket. Refer to ⇒ Rep. Gr. 26 .

Continuation for All

– Install the right drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Attach the right driveshaft heat shield to the bevel box

-arrows- and tighten it to the tightening specification. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201 .

– 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 .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

– Install the right front wheel. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 44 ; Wheel Installation Tightening Specifi‐

cations .

392

Rep. Gr.39 - Final Drive and Differential

FinalDriveandDifferential -> 3.5 Needle Bearing (polygon bearing) on Right Flange Shaft... Replacing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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