Drive shaft flange oil seal replacement instructions needed

Tiny
MALLON500
  • MEMBER
  • 2003 VOLKSWAGEN GTI
  • 1.8L
  • 4 CYL
  • TURBO
  • 2WD
  • MANUAL
  • 130,000 MILES
Fluid leak, need to know how to replace drive shaft flange oil seal.
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Monday, November 16th, 2020 AT 10:21 AM

2 Replies

Tiny
KASEKENNY1
  • EXPERT
Attached is the process for the drive flange seal. Let us know if you need more info. Thanks
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Monday, November 16th, 2020 AT 3:30 PM
Tiny
ASEMASTER6371
  • EXPERT
Good evening,

Just to add, I posted the procedure below to go along with the pictures.

Roy

4 Speed Automatic 01M

Drive flange seal, removing and installing

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Special tools and equipment
VW 391 Drive shaft fitting appliance
VW 681 Oil seal extractor
3109 Puller
3319 Thrust piece
V.A.G 1331 Torque wrench
Kukko 18/0 Puller

When replacing right-hand seal:

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Remove sound insulation tray -arrows-.
Remove right hand inner constant velocity joint protective cover from engine if fitted.
Unbolt drive shaft from drive flange.
Place drive shaft to one side and secure.
If necessary remove right-hand drive shaft

When replacing left-hand oil seal:
Loosen wheel bolts with vehicle standing on its wheels.
Raise vehicle.
Remove wheel.

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Remove left-hand sound insulation -arrows-.
Unbolt drive shaft from drive flange.

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Remove pendulum support from subframe -arrows-.
Mark installation position of ball joint bolts on left-hand control arm and remove bolts.

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Remove bolts (arrows).

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Remove left coupling rod -1- from control arm and turn rod upward.
Swing wheel bearing housing outward.
Guide drive shaft out between subframe and transmission. While guiding drive shaft out push engine/transmission assembly forward (2nd mechanic).
Lift drive shaft and secure to suspension strut with wire.

Continued for both oil seals:
Pierce sealing cap in drive flange with a screwdriver and pry out.

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Mount fitting tool and remove circlip.

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Pull off drive flange with VW 391.
Pull out drive flange oil seal with VW 681.

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Pull off drive flange for tripodic drive shaft.
Bolt puller Kukko 18-0 to flange using two 8x35 mm bolts and 8 mm diameters washers.
Pull out drive flange oil seal with VW 681.

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Pull new oil seal in onto stop with press piece 3319, M10 threaded rod (approx. 80 mm long) and nut with washer.
Fill space between sealing lip and dust lip with multi-purpose grease G 052 182 A1.
Insert drive flange, dished washer and circlip.

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Pull drive flange in.

Note: Drive flange can also be pulled in with VW 391.

Install circlip and seal drive flange with cover.
Bolt ball joint to control arm.
Secure coupling rod to control arm.
Install drive shaft.
Fit wheel.
With transmission installed, check final drive oil level.
Install sound insulation tray.

Tightening torques
Connecting link to control arm: 45 Nm (33 ft. Lb)

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Ball joint to control arm: 20 Nm (15 ft. Lb) + 90
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Monday, November 16th, 2020 AT 5:55 PM

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