Bevel Box Seals
Bevel Box Seals
=> [ Left Seal, between Bevel Box and Transmission ]
=> [ Right Seal, Drive Axle Side ]
=> [ Output Flange Seal, Bevel Box Removed ]
• The bevel box is mostly removed to replace the seals, refer to => [ Bevel Box Assembly Overview ] Bevel Box Assembly Overview. When doing this, examine all the seals closely and replace any faulty ones.
Special tools, testers and auxiliary items required
• Slide Hammer-Complete Set (VW 771) and Additional Part for VW 771 (VW 771/37)
• Pulling Hook (T20143)
• Thrust Piece (T10143)
• Thrust Piece (T10378)
• Thrust Piece (T10380)
• Grease Cap Puller (VW 637/2)
Left Seal, between Bevel Box and Transmission
• The seals (quantity: 2) can only be replaced when the bevel box is removed. Replace both seals.
Removing
- Remove the bevel box, refer to one of the following:
Passat and CC, refer to => [ Bevel Box ] Bevel Box.
Tiguan, refer to => [ Bevel Box ] Bevel Box.
Outer Seal
- Pry out the seal using (T20143/2).
Inner Seal
• To prevent the new seal from being damaged later:
- Remove the circlip - 1 - from the stub shaft.
- Carefully drive the stub shaft out - 2 - in the - direction of the arrow - using a plastic hammer.
- Remove the stub shaft seal on the transmission side.
Installing
Outer Seal
- Fill the space - arrow - between the sealing lip and dust lip of the new seal halfway with sealing grease (G 052 128 A1).
- Lightly lubricate the new seal on the outer circumference.
- Drive in the seal until seated using (T10380).
Inner Seal
- Fill the space - arrow - between the sealing lip and dust lip of the new seal halfway with sealing grease (G 052 128 A1).
- Lightly lubricate the new seal on the outer circumference.
- Drive in the seal until seated using (T10378).
- Carefully drive the stub shaft in until seated using a plastic hammer.
- Install a new circlip - 1 - on the stub shaft.
- Install the bevel box, refer to one of the following:
Passat and CC, refer to => [ Bevel Box ] Bevel Box.
Tiguan, refer to => [ Bevel Box ] Bevel Box.
- Check the axle oil in the bevel box. Refer to => [ Bevel Box Gear Oil, Checking and Filling ] 09M,09MA Transmission.
Right Seal, Drive Axle Side
• The seal can be replaced with the bevel box installed.
Removing
- Raise the vehicle.
- Remove the noise insulation under the engine/transmission.
- Remove the right drive axle.
• On some bevel boxes, a protective cap - arrow - is installed on the right side. Replace the protective cap each time it is removed.
Remove the protective cap, if equipped.
- Position the (VW 637/2) in the recess - arrow - and pry the protective cap off.
- Remove the circlip - 1 - and O-ring - 2 - from the stub shaft.
- Place a reservoir under the bevel box.
Pry out seal using (T20143/2)
Installing
- Fill the space - arrow - between the sealing lip and dust lip of the new seal halfway with sealing grease (G 052 128 A1).
- Lightly lubricate the new seal on the outer circumference.
- Drive in the seal until seated using (T10143).
- Install a new circlip and O-ring onto the stub shaft.
With a Protective Cap
- Drive the new protective cap on until seated using (T10143).
- Check the axle oil in the bevel box. Refer to => [ Bevel Box Gear Oil, Checking and Filling ] 09M,09MA Transmission.
- Install the drive axle.
Output Flange Seal, Bevel Box Removed
• The seal can only be replaced when the bevel box is removed.
Special tools, testers and auxiliary items required
• Holding Fixture (VW 313)
• Tube 42 mm Dia. (VW 516)
• Thrust Piece (40-105)
• Thrust Piece (T10049)
• Transmission Holder (T10108)
• Stop Plate (T10108/1)
• Torque Wrench (V.A.G 1601)
• 2-Arm Puller Kukko 20/10 (20/10)
• 3-Arm Puller Kukko 45-2 (45-2)
• Slide Hammer-Complete Set (VW 771)
• Additional Part for VW 771 (VW 771/37)
• Sealing Grease (G 052 128 A1)
• 2 M10 x 30 Bolts
• 2 M12 x 10 Nuts
Removing
- Remove the bevel box, refer to one of the following:
Passat and CC, refer to => [ Bevel Box ] Bevel Box.
Tiguan, refer to => [ Bevel Box ] Bevel Box.
- Set the bevel box in the hole - arrow - designated with the number - 5 - on the (T10108).
A Install the M12 x 10 nuts (Qty: 4) between the bevel box and (T10108). The nuts act as spacers.
- Align the bevel box to the hole that is opposite it and secure.
- Place the (VAS 6208) underneath.
- Drain the oil from the bevel box.
- Secure the bevel box output flange using (T10108/1) and M10 x 30 bolts - arrows -.
- Remove the output flange nut.
A Socket attachment SW 36 for 3/4 inch drive
- Pivot the bevel box so that the output shaft faces upward.
- Remove the output shaft from the bevel box shaft bevel gear.
A (45-2)
- Remove the output shaft seal - A -.
- Clean the locking fluid residue from the threads on the shaft bevel gear.
Installing
- Drive in the new seal until seated using (T10049).
- Fill area between the sealing lip and dust lip of the new seal halfway with sealing grease (G 052 128 A1).
- Pull in the output flange using (20/10) - A -.
A (20/10)
- Position the pulling hooks on the underside of the drive pinion housing.
- Lubricate the threads of the new nut with locking compound (D 000 600).
- Tighten the new nut to specification, refer to - item 10 -=> [ Nut ] Bevel Box Assembly Overview.
A Socket attachment SW 36 for 3/4 inch drive
- Install the bevel box, refer to one of the following:
Passat and CC, refer to => [ Bevel Box ] Bevel Box.
Tiguan, refer to => [ Bevel Box ] Bevel Box.
- Check the axle oil in the bevel box. Refer to => [ Bevel Box Gear Oil, Checking and Filling ] 09M,09MA Transmission.