Gasket on Intermediate Flange For Front Final Drive, Replacing

Gasket on intermediate flange for front final drive, replacing
Special tools and equipment





VAG1383A Engine/transmission jack with VAG1359/2 universal transmission mount

Removing
- Remove transfer gearbox. Removing and Installing





- Undo bolts (arrows) on intermediate flange for front drive axle.
- Dowel pins -A- and magnet -B- remain on intermediate flange.
- Slowly and carefully remove intermediate flange for front final drive from transmission housing. Otherwise gears (pinions) can drop out of transmission.
Gears which have been dropped on the floor must not be used again. If this happens, the transmission must be replaced.
- Lift off intermediate flange for drive axle.





- Do not remove drive pinion -1- (output), intermediate pinion -2- and drive pinion -3- (input) for front final drive and secure against falling out.
If the front final drive gears (pinions) are removed, the markings (arrows) on the gears for drive pinion -1- (output) and intermediate pinion -2- must face outward (away from transmission) when reinstalling.

Installing
Installation is the reverse of removal, when installing note the following:





- Make sure dowel sleeves -A- are seated correctly before installing.
- Install gasket.
- Install intermediate flange for front final drive.
Installing the intermediate flange onto the output shaft without using great care can damage the sealing lips of the seal (arrow).





- Tighten bolts (arrows) on intermediate flange for front final drive hand-tight.
- Make sure dowel pins -A- and magnet -B- are seated correctly.
- Install transfer gearbox. Removing and Installing





- Tighten bolts -A- and -C- for transfer gearbox -2- hand tight.
- Tighten bolts -B- for front final drive intermediate flange -1- and bolts -A- for transfer gearbox -2- in stages using diagonal sequence to tightening torque.
- Tighten bolts -C- for transfer gearbox to intermediate flange to tightening torque.
- Fill transfer gearbox with gear oil and check oil level.

- Fill transmission with ATF and check ATF level.






Tightening torque
Intermiate flange for front final drive transmission housing 23 Nm (17 ft. lbs.)
Transfer gearbox to transmission housing 23 Nm (17 ft. lbs.)