Seat For Flange/Driveshaft, Replacing

Seat for flange/driveshaft, replacing
Special tools and equipment





^ VAG 1383A Engine/transmission hoist with VAG 1359/2 universal mount
^ 3028 Retainer
^ VW391 Puller
^ VW771 Slide hammer-complete set
^ VW771/37
^ 3026 Mandrel





^ 3143 Seal driver-frt wheel bearing
^ Rear final drive installed

- Observe general repair notes.

Removing drive shaft
- Remove rear part of exhaust system behind clamping sleeve(s):





- Check whether there is a factory marking (color marking) on drive shaft. If not, mark location of driveshaft flange (arrow -A-) to rear final drive (arrow -B-) with color.
- Disconnect drive shaft from rear final drive and tie up at exhaust system clamps.
- Place VAG 1383A engine/transmission hoist with 1359/2 transmission support under final drive and support final drive.





- Remove securing bolts (arrows) of left transmission support.
- Lower final drive carefully until the flange is accessible.
- Mark position of securing nut for drive pinion with color.





- Measure and note following dimensions using depth gauge for check during assembly.
Dimension a = distance of flange/drive pinion
Dimension b = distance of flange/drive pinion nut

Note: The following procedure in the illustration is shown with the differential removed.





- Install 3028 retainer and remove drive pinion nut.
- Place drip tray underneath.





- Pull off flange using VW391 puller.
- Thread two hex head bolts M8 x 30 -A- into flange.





- Pull out seal.

Installing drive shaft
Installation is reverse of removal, noting the following:





- Replace O-ring between drive pinion bearing and flange.
- Lightly oil O-ring before installation.
- Lubricate area between sealing lip and dust lip with a thin layer of multipurpose grease.
- Lightly oil outer circumference of seal.





- Drive in seal for flange/drive shaft using 3026 mandrel up to stop.





- Drive flange for drive shaft far enough onto drive pinion so that securing nut can be installed.
- Clean drive pinion nut and thread at drive pinion of oil and grease residue. Lightly coat thread with locking fluid D 000 600.

Note: Use existing hex nut for securing flange to drive pinion. Otherwise the original installation position will not be found again.

- Tighten drive pinion exactly to previously marked position.





- To ensure that installation is OK, perform a check measurement of dimensions -a- and -b-.
Max. deviation from original measurement: � 0.5 mm





- Secure hex nut.
- Top off transmission fluid in rear final drive and check oil level.
- Determine radial run-out at flange/drive shaft if a factory marking (color marking) is present at the drive shaft, and align color marking on drive shaft to new marking on flange.
- If there was no factory marking on driveshaft (color marking) and position of driveshaft in relation to final drive flange was marked before removal, driveshaft must be installed in same position.

Note:
^ After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and bolt head may not be reinstalled.
^ After removing driveshaft, remove any remaining locking fluid from thread bores in the transmission drive flanges and the rear final drive. Otherwise there is a possibility that the new bolts may get jammed when installed and shear when removed.
^ Cleaning can be performed with a thread cutter.
^ Replace driveshaft bolts (self-locking).

- Replace oil seal at flange/driveshaft and tighten driveshaft.
- Install exhaust system free of stress.





Tightening torques