TIGHTENING TORQUES
| Mounting saddle for flanged shaft to transmission | 23 Nm (17 ft.lb.) |
|---|
| Coolant pipe to mounting saddle | 23 Nm (17 ft.lb.) |
| Drive shaft to flanged shaft | 39 Nm (29 ft.lb.) |
TIGHTENING TORQUES SPECIFICATIONS
Scheme 1
| No. | Designation | Special tool |
|---|
| A | Pressure piece (1) | 9615 |
| B | Inserter and puller (1) | P254 |
| (1) For explanation (Scheme 1) |
Scheme 2
Scheme 3
- Remove long flanged shaft. See «REMOVING AND INSTALLING LONG FLANGED SHAFT»(ref-199508-S20545595242005101900000) .
- Remove snap ring for ball bearing.
- Press flanged shaft out of mounting saddle.
- Lever sealing ring out of mounting saddle with large screwdriver.
Scheme 4
Scheme 5
- Push new sealing ring up to the stop with special tool 9615.
- Press mounting saddle with ball bearing onto flanged shaft.
- Insert snap ring.
- Install flanged shaft; check and top up transmission oil in final drive.
Scheme 6
| No. | Designation | Special Tool |
|---|
| 1 (1) | Hook VW | 681 |
| 2 (1) | Pressure piece | 3383 |
| (1) (Scheme 6). |
SPECIAL TOOLS DESCRIPTION
Note. A defective double sealing ring allows ATF or transmission oil to escape via the middle vent opening of the shaft seal (between the two sealing lips) into the converter bell housing. A defective double sealing ring can also let ATF enter the differential. The latter is overfilled, and oil emerges at the differential vent opening.
Scheme 7
Scheme 8
- Unbolt rear wheels.
- Remove differential. See «REMOVING AND INSTALLING THE DIFFERENTIAL (TRANSMISSION G 86)»(ref-199508-S35557424032005101900000) .
- Remove long flanged shaft. See «REMOVING AND INSTALLING LONG FLANGED SHAFT»(ref-199508-S20545595242005101900000) .
- Take bearing outer race (1) and adjusting shim (2) out of the transmission housing by hand. NOTE: The adjusting shim is calibrated and cannot be exchanged for an approximate substitute.
- Carefully pull out gasket with special tool VW 681. NOTE: Special tool VW 681 must be applied behind the two sealing lips of the sealing ring. Do not apply to the circumference of the sealing ring, since otherwise the contact area in the transmission housing will be damaged. While levering it out, guide lever carefully.
Scheme 9
Scheme 10
- Check seat of sealing ring in transmission housing for damage.
- Thinly coat circumference and sealing lip of sealing ring with Vaseline.
- Push sealing ring up on the special tool so that the projecting sealing lip (arrow) faces the special tool.
- Drive sealing ring into the stop with special tool 3383.
Scheme 11
Scheme 11: REMOVING AND INSTALLING THE DIFFERENTIAL (TRANSMISSION G 86)
| No. | Designation | Qty. | Removal | Installation |
|---|
| 1 (2) | Flanged shaft | 2 | Refer to INSTALLING . | Grease the snap ring and drive it in with a suitable mandrel (for example, special tool VW 295) |
| 2 | Snap ring | 2 (2) | Refer to INSTALLING . | Always replace |
| 3 (2) | Torx screw | 10 | | Tightening torque 25 Nm (19 ft.lb.) |
| 4 (2) | Cover for final drive | 1 | | Seal with Loctite 574 |
| 5 (2) | Differential | 1 | Can also be removed without removing the transmission | |
| 6 (2) | Speedometer-drive gear (1) | 1 | | |
| 7 (2) | Tachometer sensor (1) | 1 | | |
| 8 (2) | Toroidal sealing ring | 1 | | Always replace, lightly oil |
| 9 (2) | Transmission housing | 1 | | |
| (1) In this transmission, the speedometer-drive gear and tachometer sensor have no function. (2) For explanation (Scheme 11) |
| (1) | In this transmission, the speedometer-drive gear and tachometer sensor have no function. |
DIFFERENTIAL (TRANSMISSION G 86) COMPONENTS DESCRIPTION
Scheme 12
- Remove the flanged shaft. To do this, place a chisel or spacer "A" under the flanged shaft and pull out the flanged shaft by turning the screw "B".
