Front Flange Shaft and Driveshaft Seal, Transfer Case Installed
Front Flange Shaft and Driveshaft Seal, Transfer Case Installed
Special tools, testers and auxiliary items required
• Adapter (VW 771/44)
• Puller (T10037)
• Counterhold tool (T10172) with adapters (T10172/6)
• Final drive support (T10337)
• Thrust piece (T40114)
• Engine/transmission jack (V.A.G 1383 A)
• Used oil collection and extraction device (V.A.G 1782)
• Sealing grease (G 052 128 A1)
Removing
- On vehicles with air suspension, activate vehicle lifting mode.
- Raise vehicle.
- Remove screws and remove rear noise insulation - 2 -.
- Place Used Oil Collecting and Extracting Device (V.A.G 1782) beneath transfer case.
- If equipped, remove the bracket and balance weight (near the oil drain plug) from the transfer case. Refer to => [ Damper and Bracket, Removing from Transfer Case and Installing ] Damper and Bracket, Removing From Transfer Case and Installing.
- Remove oil drain plug - 1 - with ratchet 3/8" and drain transmission oil.
- Remove cap - 2 -.
- Mount engine/transmission jack (V.A.G 1383 A) thrust plate together with the lower transmission support (T10337) on the transfer case.
- Lift the transfer case slightly using the engine/transmission jack (V.A.G 1383 A).
There is the risk of an accident.
• The engine/transmission jack (V.A.G 1383 A) may only be used during assembly and must not sit unsupervised under the vehicle.
- Remove transmission carrier bolts - 1 - and - 2 -.
Vehicles with 4.2L FSI engine
- Remove transmission carrier. Refer to => [ Transmission Carrier and Console ] Transmission Carrier and Console.
All
- Remove bolts - arrows - at transfer case/front driveshaft connection.
- Use the counterhold tool (T10172) with the adapters (T10172/6) to do this.
- Slide driveshaft forward and together. CV joints can be moved axially.
- Tie up driveshaft to body.
- Lower transfer case slightly.
- Remove circlip - 1 -.
- Remove flange shaft - 2 - forward. To do this, swing transmission carrier slightly to side, if necessary.
If it is not possible to remove the flange shaft - A - by hand, then remove it as follows using the puller (T10037):
- Secure adapter (VW 771/44) inside the housing bore with nuts - B - and - C -.
- Attach puller (T10037) to the flange shaft - A -.
- Use the support - D - to align puller (T10037) so that it is parallel to the flange shaft - A -.
- Pull out flange shaft.
- Pry seal - 1 - out with a lever - 2 -.
Installing
Install in reverse order, paying attention to the following:
• Always replace driveshaft bolts.
- Fill area between sealing lip and dust lip halfway with sealing grease (G 052 128 A1).
- Lightly oil outer circumference of new shaft seal.
- Drive in new shaft seal as far as stop without tilting it.
- Insert flange shaft - 2 - and secure with circlip - 1 -.
• If it is not possible to install the flange shaft by hand, then carefully use a rubber hammer to install it.
• While doing this, guide the flange shaft through the components inside the transfer case (grooved ball bearing, sprocket).
- Install cover - 2 - with an O-ring.
- Tighten oil drain plug - 1 - with a socket wrench and a 3/8"extension.
- If equipped, attach the bracket and balance weight (near the oil drain plug) to the transfer case. Refer to => [ Damper and Bracket, Removing from Transfer Case and Installing ] Damper and Bracket, Removing From Transfer Case and Installing.
• Always replace the driveshaft bolts - arrows -.
- Mount the front driveshaft to the transfer case => [ Front driveshaft, installing ] Front Driveshaft.
- Use the counterhold tool (T10172) with the adapters (T10172/6) to do this.
- Install transmission carrier. Refer to => [ Transmission Carrier and Console ] Transmission Carrier and Console.
- Fill transmission oil and check oil level in transfer case. Refer to => [ Checking Gear Oil Level in Transfer Case ] Service and Repair.
- On vehicles with air suspension, deactivate the lift mode.
