Volkswagen Touareg 2004-06

Pinion Seal

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Removal & Installation



The front differential/final drive is removed together with the engine, transmission and transfer case. The procedure for this is described in this section under Engine Assembly removal and installation.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the bolts securing the driveshaft and halfshafts to the front final drive.
  4.  
  5. Remove the front final drive and place it on a workbench.
  6.  
  7. Rotate the drive pinion nut with a beam type torque wrench. Measure friction torque before loosening the drive pinion nut. Note the friction torque value. After the seal is replaced, friction torque must be restored to this value.
  8.  
  9. Remove the hex nut securing the drive shaft flange. Counterhold the flange using tool 3435 or equivalent to ease removal.
  10.  
  11. Mark the installation position of the driveshaft flange relative to the drive pinion.
  12.  
  13. Pull off the driveshaft flange. If necessary, use a slide hammer.
  14.  
  15. Pull out the sealing ring. Clean the threads on the drive pinion.
  16.  

To install:

  1. Drive in a new seal in as far as the stop; be careful not to distort the seal.
  2.  
  3. Fill the area between the sealing lip and dust lip halfway with grease G 052 128 A1 or equivalent.
  4.  
  5. Check the dust cap for damage, replace the cap if necessary.
  6.  
  7. Install the driveshaft flange, match the marks made during removal.
  8.  
  9. Coat the threads of a new nut with Loctite® 648.
  10.  
  11. Tighten the drive pinion nut until the friction torque measured prior to removal is attained. Have an assistant counterhold the flange while tightening the nut.
    NOTE
    Increase the tightening torque gradually, frequently measuring the friction torque. The friction torque measured prior to removal must not be exceeded!

  12.  
  13. The remaining installation is the reverse of removal.

    Click image to see an enlarged view

    Fig. Measure the friction torque with a beam type torque wrench



    Click image to see an enlarged view

    Fig. Mark the installation position of the driveshaft flange relative to the drive pinion



    Click image to see an enlarged view

    Fig. Have an assistant counterhold the flange while tightening the nut

  14.  

 
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