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

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two Catalytic Converters with integral front mufflers Gear Oil for Transfer Case, 0.8 L, SAE 75W90 part # G-052-145-A2 (superseded by G-052-145-S2) Seal Grease, part # G-052-128-A1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to consider for replacement during this project: Front Differential Gear Oil, 1.3 L, SAE 75W90 part # G-052-145-A2 (superseded by G-052-145-S2) Rear Differential Gear Oil, 1.5 L, SAE 75W90 part # G-052-145-A2 (superseded by G-052-145-S2)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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