Drive flange oil seal replacement

How many here have tackled this? Can it be done without the special tool that sets the seal? Thanks.

I don't have a VW repair manual on this computer to see if newer cars are different than my old Rabbits. On my 1984 VW I popped out the drive seals and popped in new ones with no special tools. Well I made myself a special tool to preload the spring washer and spring. http://www.race.nangreaves.com/golf/TM01/ch6.2.html

This may not be applicable to newer transmissions but it does explain some concepts. http://brokevw.com/flanges.html
http://vw.snapon.com/SpecialToolsDetail.aspx?itemid=2610007
http://www.germanautoparts.com/Tools/Volkswagen/Clutch+&+transmission+tools
http://www.mk1dubz.com/forums/showthread.php?t=947

I thought I found a leak there recently but am not 100% convinced yet.
Edit; passenger side.

Ah crap.. I found a leak on my Pass side output flange 3 weeks ago, I was hoping it was a random event ??

I pulled the CV shaft, removed the flange, and checked the seal. I could find no damage. I put it all back together and refilled with Mobil 1 75W90 gear oil, a temporary patch until I can find parts, and a tool to install the seal.
1000+ miles since then, doesn't appear to leak anymore ?! although I cannot explain why.

One oddity, the small bearing race on the output flange was 'gritty' when turned. I flushed it with 75w90 a few times and it seemed to improve. The replacement is ~$350 complete with the output flange.. so I decided if it fails it is getting a 6sp, I am done with the auto. 178k and still running, but I am not sinking more into it.

Anyone else with this leak ?? seems like 3 right here..grrr

GreenT which side. Passenger side is doable. Driver side is more involved

vwztips said:

GreenT which side. Passenger side is doable. Driver side is more involved

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Passenger side. Bentley shows a special tool to install the seal. I had to replace one of these before on an Audi. Without the tool it was difficult to set the seal at the right depth and keep it straight.

Passenger side is really easy. No need to remove axel. Turn steering wheels +/- 15 degrees to the left, unbolt the axel from the flange, and move the axel rearward. Remove center bolt from flange and pull the drive flange out.

Charlie t-------------lots of used ones available

zzdiesel said:

Charlie t-------------lots of used ones available

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Did you look at the date of CharlieT's post. Pretty sure he's fixed it by now...

yes, old post revived...I bought an 05 wagon with 124k on it, the right flange seal was leaking, I pulled the flange and the bearing on the flange shaft wouldn't rotate, I cleaned it up, lubed it but still it had a flat spot. I believe it was running dry. New one $293, easy install. I have no idea on the design purpose for this bearing?

Funny, I did not, Has he??