Looks like I have a leaky drivers side output flange seal:

Would I be right in saying that this will be a pretty easy job? I'm guessing it's: Unbolt driveshaft from flange, remove flange bolt, remove flange, pull out seal and replace.

Has anyone else done this, and did you need any funny tools to remove/replace the seal?

I'm assuming this is the seal: http://www.ecstuning.com/Volkswagen-Golf_IV--1.8T/Drivetrain/Transmission/Seal/ES6200/

I notice there is also a sleeve/bushing on the drivers side flange only (the black bit in the photo, between the flange and the housing). Anyone know if this will need removing/replacing too?

I was under the car during the week, and it looks like there's a fair amount of room to do the job. Strangely there is oil on components above the diff housing, which had me thinking it was the rocker cover gasket. But somebody has pointed out to me that if oil drips from the diff housing it could get blown up the back of the engine by the high air pressure in that region during driving, which does make sense.

Thanks in advance for the feedback

is there splatter of the oil all over the place? Only reason I ask is that I thought I had a leaking drive shaft seal but it was actually oil coming from the cam cover gasket running down the block and resting on the seal. I'd get both drive shaft seals done at the same time

Yeah I suppose it could still be the rocker cover gasket as I first thought. I need to have a proper look at the back of the head, for any obvious signs of oil weeping out.

Might just change it all anyway, to be sure!

I've been using my mates pit recently, which will be perfect for changing the output seals on the gearbox. I have loads of jobs building up for the car, so DST and warmer weather should help me along!

I'm sure someone on here changed their output seals recently, but I can't remember who it was dammit!

Bodge. I had mine done recently, I was going to do them myself but the cost of the tools I needed to do it was about the same as an hours labour at a garage so I got them to do it! I had both done at the same time and had the gearbox drained and refilled completely rather than just topping up.

Edited 29 March, 201115 yr by tarmacsurfer

Bodge. I had mine done recently, I was going to do them myself but the cost of the tools I needed to do it was about the same as an hours labour at a garage so I got them to do it! I had both done at the same time and had the gearbox drained and refilled completely rather than just topping up.

Ahhar so it was you then! By tools do you mean specialist seal pullers/presses, or more standard tools like spline drive sockets and torque wrenches?

I changed the gearbox fluid last year, but if I'm topping it up I way aswell drain it again too I guess.

Can you remember how much the seals were roughly?

Ahhar so it was you then! By tools do you mean specialist seal pullers/presses, or more standard tools like spline drive sockets and torque wrenches?

I changed the gearbox fluid last year, but if I'm topping it up I way aswell drain it again too I guess.

Can you remember how much the seals were roughly?

I mean spline drive sockets etc, I was told if you are just doing topping up you should only need about half a litre. The seals were about £3 for one side and £11ish for the other...

I mean spline drive sockets etc, I was told if you are just doing topping up you should only need about half a litre. The seals were about £3 for one side and £11ish for the other...

Nice one, cheers buddy

i did mine and posted a how to on a thread, the drivers side is a bit awkward due to the black seal trim.

i did mine and posted a how to on a thread, the drivers side is a bit awkward due to the black seal trim.

Ah nice, I'll have a search for that. Unless you can find it easily...

That black sleeve thing on the drivers side can be removed and replaced too from what I've seen. Looks like you just lever it out with a screwdriver, and tap the new one in. So you think it would make the job much easier if I removed that first then?

Found it! Cheers Furry.

replaced mine when i did the clutch as mine where weaping

passenger one is about £3 and the other about £13.00 because it comes in a housing,

easy enough to change,and can be done with the box still in situ.

Once the shaft is unbolted from the joint there is a splined bolt in the middle of the box flange. undo that bolt and pull the flange out.

pull the old seal out and then tap the new seal in carefully so not to damage it.

bolt the flang back in and then the shaft back onto the flange.

don't forget to top the gear oil up when done.

the drivers side is a bit more fiddly but essentially the same proceedure.

when the drivers side one leaks it sprays oil onto the turbo which isn't nice!!!

Ordered all the bits today, so I'll sort it this weekend.

Part numbers:

Oil seal kit (seal and sleeve for RH flange) - 02J409528A - £12.23 (LH flange uses the same seal from this kit)

Driveshaft to output flange bolts - N90441103 - £0.77 each (you need 6/side)

Output flange retaining bolt - 02J409359 - £2.38 each (1/side)

Gearbox oil - G060726A2 - £5.48 (1 litre bottle)

I'll try and get some pics, incase anyone else wants to do this job.

Just for future reference:

The driveshaft bolts are: M10x1.5 and have a Triple Square (XZN) size 10 head. They are NOT spline drive as some people claim.

The output flange retaining bolt is: M8x1.25 and has a 6mm Hex socket head.

The reason I've been finding this out is so I can get the tools I need, and also make a sleeve/bush installation tool. Anyone can easily make the installation tool with some standard M8 studding, a metal disc with an 80mm OD, and an M8 nut and washer. I have all this stuff to hand anyway, so it makes sense to do it this way. The metal disc from my rear beam bush installation tool fits the seal sleeve perfectly, so I'll be using that. This method is obviously better than knocking it in with a mallet, as it will pull the sleeve in perfectly straight first time, and work much quicker. I'm guessing I'll need about 6" of studding for it.

Once I've assembled the tool later, I'll pop some pics up so others can copy it.

Ordered all the bits today, so I'll sort it this weekend.

Part numbers:

Oil seal kit (seal and sleeve for RH flange) - 02J409528A - £12.23 (LH flange uses the same seal from this kit)

Driveshaft to output flange bolts - N90441103 - £0.77 each (you need 6/side)

Output flange retaining bolt - 02J409359 - £2.38 each (1/side)

Gearbox oil - G060726A2 - £5.48 (1 litre bottle)

I'll try and get some pics, incase anyone else wants to do this job.

Does the oil seal kit come with seals to do both sides? Little confused how its been written.

Can anyone confirm this please?

Does the oil seal kit come with seals to do both sides? Little confused how its been written.

No and whilst the LH side looks like the one in the kit (RH) it is part of the seal/sleeve assembly.

From memory (so check), the LH seal (there is no sleeve) is part 02J409189A.

Ok thanks

Is there a special way to put these seals in. I done it last time with a hammer but I must of broke the sill. Tried again with new seal knocking the outer rubber and I pushed it off the metal bit n dropped it on the floor. Now its knackered n I need a new one again. Well annoyed! Anyone help?

Is there a special way to put these seals in. I done it last time with a hammer but I must of broke the sill. Tried again with new seal knocking the outer rubber and I pushed it off the metal bit n dropped it on the floor. Now its knackered n I need a new one again. Well annoyed! Anyone help?

see post #12. You need some form of seal driver. If you twist the seal whilst installing it, then it is toast. You also need to fill half the space between the seal proper and the dust lip with grease. Make sure the flange shaft goes in true.

I didn't even know there was such a thing lol. I will Google them and get myself one. Cheers

Something like this?

Check out this item I found on eBay: http://pages.ebay.com/link/?nav=item.view&id=330980331357&alt=web