General Information: Components

O-rings, Gaskets and Seals

• Always replace O-rings, gaskets and seals.
• Always clean separation surfaces.

Before Installing

• Before installing the radial shaft seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with sealing grease G 052 128 A1.
  Fig 1: Identifying Oil Seals Sealing Lips

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• Before installing the flange shaft/driveshaft radial shaft seals, lightly lubricate the outer circumference and the space between the sealing lips with high performance Haldex clutch oil.
• The open side of the gaskets points toward the fluid to be sealed in.

After Installation

• Axle oil level in rear final drive, checking REAR FINAL DRIVE OIL LEVEL, CHECKING AND FILLING .
• Check the oil level in the Haldex clutch HALDEX CLUTCH OIL LEVEL, CHECKING .

Circlips

• Do not over stretch circlips.
• Always replace damaged or overstretched circlips.
• Circlips must be properly seated in the base of the groove.
• Replace spring pins. Installation position: Slit -A- should in line with the line of force -arrow-.
  Fig 2: Identifying Locking Elements

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolts and Nuts

• Replace self-locking bolts and nuts.
• Loosen and tighten bolts and nuts for securing covers and housing parts in diagonal sequence.
• Clean screws installed with locking compound with a wire brush. Replace with locking compound AMV 185 101 A1.
• Remove locking compound residue in threaded holes with a thread tap. Otherwise, screws may shear off during next removal.
• Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.
• The tightening specification stated apply to non lubricated nuts and bolts.
• Only wax all the contact surfaces on the threaded connection bolts and nuts after installing.

Mount

• Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
• Lubricate all gearbox bearings with gear oil.
• Taper roller bearings fitted to one shaft must be replaced as a set. Use same make of bearings.
• Heat inner races to approximately 100° C before installing.
• Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.

Adjusting Shims

• Measure shims at several points using a micrometer. Varying tolerances make it possible to measure the required shim thickness exactly.
• Inspect for burrs and signs of damage.
• Install only shims that are in perfect condition.