Volkswagen Golf Variant / Jetta. Manual - part 302

 

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Volkswagen Golf Variant / Jetta. Manual - part 302

 

 

– Pivot the bevel box so that the output flange faces upward.
– Remove the output flange and the inner race/tapered roller

bearing from the bevel box shaft bevel gear.

A - Puller Three-Arm , for example Three-Arm Puller - 45-2-

– Please note the different installation locations for the output

flange seals:

The Output Flange Seal -arrow- is Inside the Pinion Housing.
Output flange seal in pinion housing, removing and installing. Re‐

fer to

⇒ Fig. ““Output Flange Seal in Pinion Housing, Removing and

Installing”“ , page 384

 .

The Seal -arrow- is Located on the Output Flange.
Output flange seal, removing and installing. Refer to

⇒ Fig. ““Output Flange Seal -arrow- Removing and Installing:”“ ,

page 385

 .

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

383

• The inner race/tapered roller bearing must be removed from

the output flange:

– Place the Press Piece - Multiple Use - 40-105- on the output

flange.

– Remove the inner race/tapered roller bearing from output

flange with the Tapered Roller Bearing Puller - VAG1582- .

Note

Instead of the Puller - Taper Roller Bearing - Adapter 6 -

VAG1582/6- , the Puller - Taper Roller Bearing - Adapter 6A -

VAG1582/6A- can be used.

Install Seal and Output Flange
– Cover pinion housing with a lint-free cloth.
– Clean any remaining locking fluid from the thread on the shaft

bevel gear.

• If the shim -2- is removed during the removal of the output

flange, place it back in the pinion housing.

• This will maintain the bearing pre-load on the shaft bevel gear

-1- inside the pinion housing.

– Insert the previous inner race/tapered roller bearing -3- in the

outer race/tapered roller bearing into the bevel box.

– Lightly lubricate the outer circumference of the new output

flange sealing ring -4-.

– Drive in the new seal using Seal Installer - Flange Shaft -

T10049- .

• The seal must be flush with the upper edge of the housing.
– Fill the space between the sealing/dust lip halfway with Seal‐

ing Grease - G 052 128 A1- .

384

70-180mm - 20/10-
Note the following:
• Do not use a damaged extractor hook.
• The output flange may not be on edge when pulling out the

shaft bevel gear.

• Mount the hooks on the bottom of the pinion housing.
• Tension the removal hook with the Two-Arm Puller -arrows-.
• Do not bend the removal hook toward the outside.
• Interrupt the procedure if necessary, remove the output flange

again and repeat the process.

Output Flange Seal -arrow- Removing and Installing:
Seal, Removing

• When removing the output flange seal, the inner race/tapered

roller bearing must also be removed.

– Place the Press Piece - Multiple Use - 40-105- on the output

flange.

– Remove the inner race/tapered roller bearing from output

flange with the Tapered Roller Bearing Puller .

– Remove the output flange seal.

Seal, Installing
• First remove the pinion housing -1- along with the shaft bevel

gear -2- in order to install the seal:

– Remove the bolts for the pinion housing -1-; and carefully re‐

move the pinion housing diagonally of the protruding edges.

– Remove the pinion housing and the shaft bevel gear -2-.
– Clean the thread on the shaft bevel gear.
• If the shim -3- was also removed during the removal of the

output flange, it must be placed back in the pinion housing.

• This will maintain the bearing pre-load on the shaft bevel gears

inside the pinion housing.

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

385

ion housing.

– Lightly lubricate the outer diameter of the new output flange

seal -2-.

– Drive in the new seal using Seal Installer - Flange Shaft -

T10049- .

• The seal must be flush with the upper edge of the housing.
– Fill the space between the sealing and dust lip of the seal half‐

way with Sealing Grease - G 052 128 A1- .

– Press in the output flange along with the pinion housing and

shaft bevel gear all the way.

• The shoulder -arrow- of the Press Piece - Multiple Use -

VW455- points to the shaft bevel gear.

– Install the M 8 X 30 mm stud bolts = -A- or Guide Pins - M8 -

T10273- into the axle drive housing.

– Slide a new O-Ring -1- onto the pinion housing -2-.
The pinion housing -2- and shim -3- only fit in one position.
– Install the previous shim -3-.
– Carefully install the pinion housing diagonally all the way with

Removal Device - Pin 2 - VW460/2- .

There is very little space between the pinion housing and the

bevel box housing.
The gap is closed when the pinion housing is tightened.
– Tighten the bolts for the pinion housing -2- diagonally.
Tightening Specification -item 21- 

⇒ Item 21 (page 379)

 .

Continuation for All

386

 

 

 

 

 

 

 

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