Front Final Drive Assembly Overview
Front Final Drive Assembly Overview
• Rules of cleanliness for working on automatic transmissions => [ Clean Working Conditions ] Clean Working Conditions.
• General repair notes => [ General Repair Instructions ] General Repair Instructions.
1 Shaft seal
• Between final drive and transmission housing
• Replace => [ Final Drive/Transmission Housing Shaft Seal ] 09EA Transmission
2 Adjustment shim
• Behind outer race for tapered roller bearing
3 Outer race for tapered roller bearing
4 O-Ring
• Replace
5 Sealing plug, 35 Nm
• Replace
6 Right drive flange
• Removing and installing => [ Right Flange Shaft, Removing and Installing ]
7 Circlip
• Replace
8 Right flange shaft seal
• Replace => [ Right Flange Shaft Seal ] 09EA Transmission
9 Bolt, 23 Nm
• Observe tightening sequence => [ O-Ring on Final Drive Cover ] 09EA Transmission
10 Cover for final drive
11 Adjustment shim
• Behind outer race for tapered roller bearing
12 Outer race for tapered roller bearing
13 Final drive cover O-ring
• Replace => [ O-Ring on Final Drive Cover ] 09EA Transmission
14 Differential
15 Spring pin
16 Selector shaft lever
17 Selector shaft seal
• Replace => [ Selector Shaft Seal ] 09EA Transmission
18 Bolt, 23 Nm
19 Flange shaft, left
• Removing and installing => [ Left Flange Shaft, Removing and Installing ]
Right Flange Shaft, Removing and Installing
• Rules of cleanliness for working on automatic transmissions => [ Clean Working Conditions ] Clean Working Conditions.
• General repair notes => [ General Repair Instructions ] General Repair Instructions.
Special tools, testers and auxiliary items required
• Old oil collecting and extracting device (V.A.G 1782)
Removing
• Transmission installed.
- Remove heat shield for right drive axle.
- Remove right drive axle from transmission flange and tie up
- Place old oil collecting and extracting device (V.A.G 1782) beneath transmission.
- Remove flange shaft by placing a chisel or spacer piece - A - under flange shaft and by turning bolt - B -.
• If difficult to remove, rotate flange shaft and install bolt into opposite threaded hole for removal of flange shaft.
- Always replace flange shaft circlip.
- Clamp flange shaft in vise, using jaw protectors. Press circlip with new circlip - A - out of flanged shaft groove.
Installing
- Clean flange shaft and shaft seal.
- If shaft seal is damaged, it must be replaced => [ Right Flange Shaft Seal ] 09EA Transmission.
- Fill area between sealing lip and dust lip halfway with sealing grease (G 052 128 A1).
- Insert flange shaft by hand into front final drive splines until splines lock properly into place.
- Press flange shaft in by hand or with needle bearing drift (VW 295) as far as stop.
• The circlip of flange shaft must be engaged.
- Install right drive axle.
- Install heat shields for drive axle.
- Checking gear oil level in front final drive => [ Separate and Combined Fluid Systems ] Separate or Combined Oil Systems, Differentiation.
Torque specification
Left Flange Shaft, Removing and Installing
• Rules of cleanliness for working on automatic transmissions => [ Clean Working Conditions ] Clean Working Conditions.
• General repair notes => [ General Repair Instructions ] General Repair Instructions.
Special tools, testers and auxiliary items required
• Old oil collecting and extracting device (V.A.G 1782)
• Puller (T10037)
Removing
• Transmission is removed
• Transmission fastened to assembly stand => [ Transmission, Securing to Assembly Stand ] Transmission, Securing to Assembly Stand
CAUTION!
The transmission must not be set down on the ATF cooler or oil pan.
- Remove bolts - arrows - on left flange shaft mounting bracket.
- Place old oil collecting and extracting device (V.A.G 1782) beneath transmission.
- Remove left flange shaft by fastening Puller (T10037) to transmission housing - arrow -.
- Using puller (T10037), pull flange shaft out only so far until bearing on shaft is removed from transmission housing.
• If the shaft is not held centered - arrow - during further removal, the shaft splines fall onto the inner shaft seal between the final drive and the transmission housing. The shaft seal will be damaged and will have to be replaced => [ Final Drive/Transmission Housing Shaft Seal ] 09EA Transmission.
- Pull flange shaft - A - out of transmission, ensuring shaft remains centered in the opening on front final drive - arrow -.
Installing
- Installation is in reverse order of removal.
Perform and observe the following test steps.
- Clean flange shaft and shaft seal.
- If shaft seal between final drive and transmission housing is damaged, it must be replaced => [ Final Drive/Transmission Housing Shaft Seal ] 09EA Transmission.
- Fill area between sealing lip and dust lip halfway with sealing grease (G 052 128 A1).
- Insert flange shaft - A - into transmission and guide shaft into shaft seal on front final drive - arrow -, keeping shaft centered.
• If the shaft is not held centered, the splines of the shaft will damage the shaft seal between final drive and transmission housing. The shaft seal must then be replaced => [ Final Drive/Transmission Housing Shaft Seal ] 09EA Transmission.
Torque specification
