fluid leak, need to know how to replace drive shaft flange oil seal.
Nov 16, 2020 at 10:21 AM
drive shaft flange oil seal replacement instructions needed
2003 VOLKSWAGEN GTI
MALLON500
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Attached is the process for the drive flange seal. Let us know if you need more info. Thanks
Images (Click to enlarge)
Nov 16, 2020 at 3:30 PM
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
imageOpen In New TabZoom/Print
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:
imageOpen In New TabZoom/Print
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.
imageOpen In New TabZoom/Print
Remove left-hand sound insulation -arrows-.
Unbolt drive shaft from drive flange.
imageOpen In New TabZoom/Print
Remove pendulum support from subframe -arrows-.
Mark installation position of ball joint bolts on left-hand control arm and remove bolts.
imageOpen In New TabZoom/Print
Remove bolts (arrows).
imageOpen In New TabZoom/Print
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.
imageOpen In New TabZoom/Print
Mount fitting tool and remove circlip.
imageOpen In New TabZoom/Print
Pull off drive flange with VW 391.
Pull out drive flange oil seal with VW 681.
imageOpen In New TabZoom/Print
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.
imageOpen In New TabZoom/Print
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.
imageOpen In New TabZoom/Print
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)
imageOpen In New TabZoom/Print
Ball joint to control arm: 20 Nm (15 ft.lb) + 90°
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
imageOpen In New TabZoom/Print
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:
imageOpen In New TabZoom/Print
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.
imageOpen In New TabZoom/Print
Remove left-hand sound insulation -arrows-.
Unbolt drive shaft from drive flange.
imageOpen In New TabZoom/Print
Remove pendulum support from subframe -arrows-.
Mark installation position of ball joint bolts on left-hand control arm and remove bolts.
imageOpen In New TabZoom/Print
Remove bolts (arrows).
imageOpen In New TabZoom/Print
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.
imageOpen In New TabZoom/Print
Mount fitting tool and remove circlip.
imageOpen In New TabZoom/Print
Pull off drive flange with VW 391.
Pull out drive flange oil seal with VW 681.
imageOpen In New TabZoom/Print
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.
imageOpen In New TabZoom/Print
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.
imageOpen In New TabZoom/Print
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)
imageOpen In New TabZoom/Print
Ball joint to control arm: 20 Nm (15 ft.lb) + 90°
Nov 16, 2020 at 5:55 PM
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