2004 VW Phaeton W12 5-Speed Transmission Rear Seal ...

[Pages:15]2004 VW Phaeton W12 5-Speed Transmission Rear Seal Replacement Procedure

1. Preparation and Tools needed for this project:

This procedure applies to the 5-speed ZF 5HP-24A, Code FGE, transmission installed in a 2004 Phaeton with the W12 engine. This probably applies to 2005 & 2006 W12 Phaetons also but can't verify it.

Related VWVortex Threads:

Naming of parts:

1. Transfer Case 2. Transfer Case Flange 3. Transfer Case Flange Housing 4. Front Driveshaft Flange 5. Rear Driveshaft Flange 6. Rear Final Drive 7. Rear Final Drive Flange

Parts needed:

Transmission Rear Seal at drive shaft flange 12 Driveshaft Mounting Bolts, part # N-019-926-1 Seal between Transmission tail shaft/transfer case and drive shaft flange housing (optional) Seal at front & rear end of drive shaft (optional if original seal is not damaged) 2 exhaust gaskets at upstream end of the two Catalytic Converters with integral front mufflers Gear Oil for Transfer Case, 0.8 L, SAE 75W90 part # G-052-145-A2 (superseded by G-052-145-S2) Seal Grease, part # G-052-128-A1

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Additional parts to consider for replacement during this project: Front Differential Gear Oil, 1.3 L, SAE 75W90 part # G-052-145-A2 (superseded by G-052-145-S2) Rear Differential Gear Oil, 1.5 L, SAE 75W90 part # G-052-145-A2 (superseded by G-052-145-S2)

Tools needed: 10 mm Socket 13 mm Socket 17 mm Socket 1-1/2" Socket (1/2" drive) 6 mm Hex Bit 8 mm Hex Bit 8 mm Hex Key, long reach (and extension would be very useful too) 10 mm Hex Key, long reach (for Rear Differential Oil Fill & Drain Plug) Torx T27 Socket Torx T27 Drive Bit and Mini Ratchet Torx T40 Socket (2) M10 x 1.5 x 100 Bolts (Class 10.9 preferred, Class 8.8 will get bent) Various length extensions for 3/8" drive Long Pry Bar Seal Puller (needed if Transfer Case Flange Housing is not removed) Pressure Filler Oil Transfer Pump Brake Cleaner Penetrating Oil

2. Check that Gear Oil Fill Plug can be removed:

Loosen but don't remove gear oil fill plug, 8 mm hex bit, at RH side of transfer case. Use a long reach 8 mm hex key because there is not enough clearance to get a socket & wrench on it. This step is very important because if the oil gets drained first and then the fill plug won't come out there is no way to fill the transfer case with oil!

3. Removing Exhaust System:

Raise car off the ground with a lift. Putting the car on jack stands or ramps will make this procedure extremely difficult to near impossible due to access issues.

This procedure covers only the removal of both Catalytic Converters with integral front mufflers. It is also possible to remove the whole exhaust system from the Catalytic Converter with integral front muffler on back but that will require removal of the rear bumper cover and alignment of the exhaust system during reinstallation.

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 Support LH Catalytic Converter with integral front muffler and mark location of double clamp. Loosen two bolts, 2x 17 mm, at Double Clamp on downstream end of LH Catalytic Converter

with integral front muffler and spray a little penetrating oil on the Double Clamp

Unbolt 3 bolts, 3x 13 mm, on upstream flange of LH Catalytic Converter w/ integral front muffler Wiggle and slide back LH Catalytic Converter with integral front muffler until the studs clear the

flange, then move it to the side and slide it forward and out of the Double Clamp. Remove assembly from car and discard exhaust gasket at front flange. Remove Double Clamp. Repeat the same steps for the RH Catalytic Converter with integral front muffler

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 It will look like this once the front mufflers are removed:

Temporarily Support Center Muffler Remove 4 bolts, 4x 13mm, securing exhaust hangers at center muffler to car body.

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 Remove temporary support and carefully lower rear exhaust system by about one foot and then support it at that level.

4. Remove Heat Shields and Driveshaft:

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 Remove all 10 bolts, 10x 10 mm, from the perimeter of front & rear center Heat Shields Support the driveshaft in the center then remove the two bolts, 2x 13 mm, securing the center

driveshaft support. Lower the driveshaft just enough for the heat shields to be removed. Remove front & rear center heat shields from car. Re-attached center driveshaft support, 2 bolts, 2x 13 mm , only secure bolts hand tight.

Remove Shielding Plate at front end of Driveshaft, 3 bolts, 3x T27. Check on markings on driveshaft, if non found then mark driveshaft and driveshaft flange and

also driveshaft flange to transmission housing Remove Shielding Plate at rear end of Driveshaft, 2 bolts, 2x 8 mm hex bit. Screw two temporary M10 x 100 bolts into rear final drive housing, use the holes for the

Shielding Plate attachment.

Loosen driveshaft to driveshaft flange bolts, 6 bolts, 6x 6mm hex bit, at front end of Driveshaft. Use a pry bar as a lever to counterhold the driveshaft and prevent it from turning.

Setup a support for the front part of the driveshaft, then remove the 6 bolts, 6x 6mm hex bit, and 3 lock plates and disconnect driveshaft from flange being careful as not to damage the gasket on the driveshaft. Driveshaft flange will not clear the black rubber trans seal housing at this point.

Remove 6 bolts, 6x 6mm hex bit, and 3 lock plates at rear end of Driveshaft. Use a pry bar as a lever to counterhold the driveshaft and prevent it from turning.

Setup a support for the rear part of the driveshaft.

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 Remove temporary M10 x 100 bolts from rear final drive housing. Setup support for center driveshaft support bracket and then remove, 2 bolts, 2x 13 mm, from

center driveshaft support. Together with a helper take the driveshaft, drop the rear end down and to the side, slide it back

a bit until it clears the transmission flange housing in the front. Lower the front driveshaft so it clears the exhaust flanges and then carefully pull the whole driveshaft forward and out. Set the driveshaft aside and make sur it's supported so it stays straight and is not bent too much. It will look like this once the driveshaft is removed:

5. Draining Gear Oil out of the Transfer Case:

Remove gear oil fill plug, 8 mm hex bit, at RH side of transfer case. Use a long reach 8 mm hex key because there is not enough clearance to get a socket & wrench on it. This step is very important because if the oil gets drained first and then the fill plug won't come out there is no way to fill the transfer case with oil!

Place drip tray below oil drain plug. Use a clean one if drained gear oil is to be reused. Remove gear oil drain plug, 6 mm hex bit, at bottom of transfer case and drain oil. Reinstall gear oil drain plug, 6 mm hex bit. Reinstall gear oil fill plug, 8 mm hex bit, to prevent contamination of transfer case

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6. Replacing Transmission Rear Seal:

Temporarily re-install 2 bolts, 2x 6mm hex bit, and 1 lock plate into the transfer case driveshaft flange.

Remove one bolt in the center of the driveshaft flange, 1 x T40, M8. Use a pry bar as a lever to counterhold the driveshaft flange and prevent it from turning.

Remove driveshaft flange from transmission/transfer case output shaft by carefully pulling it backwards. Carefully use a pry bar on the bolts to help with pulling it back if it seems stuck.

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