Volkswagen Cars 2000-05

Pinion Seal

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Removal & Installation




WARNING
Exercise great care if removing the drive flange and the mounting nut from the differential pinion shaft as the amount of torque applied will change the preload of the differential bearings and the mesh of the final drive gears. Improper assembly could result in severe internal damage.

  1. Raise and safely support the vehicle.
  2.  
  3. Matchmark the driveshaft to the drive flange with paint, then remove the drive shaft and support it out of the way.
  4.  
  5. Support the differential with a suitable transmission jack.
  6.  
  7. Remove the front support bracket fasteners and carefully lower the front of the differential until the flange nut is accessible.
  8.  
  9. Matchmark the flange lock nut with paint.
  10.  


WARNING
The flange nut MUST be matchmarked with paint otherwise its original installation position will be lost!

  1. Measure the distance of the topmost portion of the flange nut to the flat surface of the drive flange and write the measurement down.
  2.  
  3. Measure the distance of the top of the flank of the flange nut to the flat surface of the drive flange and write the measurement down.
  4.  


NOTE
The flange nut must be reused for proper installation.

  1. Using Tool No. 3028, or its equivalent, support the flange and remove the nut. Loosen and remove the nut by hand.
  2.  
  3. Place a suitable drain pan under the differential and remove the drive flange using Tool No. VW391, or its equivalent.
  4.  
  5. Remove the oil seal, and then remove the O-ring from the splined shaft.
  6.  



Click image to see an enlarged view

Fig. Proper installation of the flange lock nut is critical. Compare the measurements before and after installation

To install:

  1. Install a new O-ring lubricated with gear oil on the splined shaft.
  2.  
  3. Install a new seal into the housing until it is fully seated, then coat between the inner sealing and dust lips of the seal with a light coating of multi-purpose grease. Do NOT use wheel bearing grease.
  4.  
  5. Carefully seat the drive flange onto the splined shaft.
  6.  
  7. Clean the threads of the lock nut and splined shaft thoroughly with rubbing alcohol or brake cleaner and allow to dry.
  8.  
  9. Apply a light coating of a locking agent, such as Part No. D 000 600.
  10.  
  11. Install the lock nut and tighten to its original position.
  12.  
  13. Repeat the measurements taken between the of the topmost portion of the flange nut to the flat surface of the drive flange and the top of the flank of the flange nut to the flat surface of the drive flange and write the measurements down. The measurements must not differ by more than 0.02 inches (0.5mm).
  14.  
  15. Secure the nut by staking the outer surface with the splined shaft.
  16.  
  17. The balance of the installation is in reverse order of removal noting the following:
  18.  
  19. Observe the following torque specifications:
  20.  


    Differential-to-front mount: 30 ft. lbs. (40 Nm)
     
    Driveshaft-to-differential: 41 ft. lbs. (55 Nm)
     

  21. Upon completion, check and top off the differential fluid level using an approved lubricant.
  22.  

 
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