02A/02C/02J Reassembly Part 2 of 3

[@justinmelton3777]

You posted these vids forever ago and I have used them several times over the past few years. Thanks again for all the help!

[@andrewlewis4253]

I'm still rallying that trans too! Glad folks got something out of my videos.

[@jonathanwoods9843]

I have a green B4 wagon that looks almost exactly like yours. The right side axle flange seal was leaking, so I replaced it. My car has the push-in style axle flange that has the circlip that goes into the groove at the end. I've inserted the flange into the differential and driven it in. I couldn't create enough force to drive in the flange with the limited space working beneath the car, so I used a long iron pipe from outside the car, having first removed the brake rotor for clearance. I've hit the pipe with a 5 lb hammer quite hard several times, which has driven in the axle flange, but there is still about 1/4" (maybe slightly less) of the shiny, machined part of the axle flange shaft still showing between the axle seal and the cup part of the flange. Prior to removal, the cup part was right against the seal. I'm hitting it as hard as I can, and can't get the flange to go in further. As I'm unfamiliar with doing this, I don't know if it requires even more force to get the axle flange seated, or if it already is seated. What do you think?

[@andrewlewis4253]

The most important thing is that you can't move it out. If it's locked in then leave it alone. My 02C passenger side axle cup is about 16" long and is rifle drilled for a bolt to hold it in (I'm using the 02C 17/27 angled drive from a Skoda so it is bolt-on). My Peloquin differential is 02C but the original 02C angled drive was a push-on like yours. My axle kept wandering out and letting gear oil out so my solution was I made a bracket that has a large roller bearing that bolts to the block and physically pushes the cup. It's worked for years now but it was supposed to be temporary until I removed the trans, disassembled it, and had the diff drilled/tapped for that bolt. The moral of my story relates to the fact that axle cup can move in and out a good 1/2" and still not leak. It shouldn't take but a couple blows from a dead blow hammer to get it seated. What I believe you have done is installed the seal 1/4" deeper than the old seal, thus you are seeing shiny bits. Leave it alone, monitor for leakage, and drive it!

[@jonathanwoods9843]

@@andrewlewis4253 Thanks for answering. I looked up all the 02a pics and videos I could find, and every one looks like I described. I think the reason it was pushed in further was because of an earlier screw-up: When I had the axle out to repack the cv joints and replace the boots, I hadn't engaged the axle splines with the hub on that axle. The axle had been held to the hub by the nut with the hub splines jammed against the axle splines. This preloaded the axle flange, which worked its way inwards toward the transmission. What's amazing is that I drove for years like this, even did a couple of track days, and it seemed fine. I didn't discover it until I changed the wheel bearings a couple of years ago. I've had the car for many years, and this axle seal had been leaking ever since I bought the car. I'd avoided changing this seal because it looked like it probably wouldn't be easy- I was right about that! Hopefully, this new seal will keep from leaking like the one on the other side has ever since the car was brand new in 1996.

[@EnzoFava]

Thank you so so much Andrew!! :D

[@coreycrosswhite8890]

Did you use new bearings, I'm assuming you did

[@andrewlewis4253]

If they pass visual inspection reuse them. I've since put 120k miles on that trans and no metal in the 2 fluid changes thus far. Use quality oil and refrain from dropping the clutch and all will be well. Bearings are a wear item and can be reused pending visual inspection approval.

[@coreycrosswhite8890]

@@andrewlewis4253 why did you need to reshim if useing the same bearings, only 2 oil changes In 120000 miles I change mine every 30000

[@andrewlewis4253]

@@coreycrosswhite8890 I used a different case from what the guts came from. Variations in case tolerances during manufacturing means you have to re-shim. 30k oil changes are excessive. Even DSG is 40k.