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Pelican Technical Article:

Rear Main Seal Replacement

Jared Fenton

Time:

8 hours8 hrs

Tab:

$35

Talent:

*****

Tools:

5mm hex driver, silicone RTV adhesive, floor jack, jack stands, wheel chocks, safety glasses, torque wrench

Applicable Models:

VW Beetle (1998)
VW Beetle GL (1999-05)
VW Beetle GLS (1999-05)
VW Beetle Sport (2001-02)
VW Cabrio (1998-99)
VW Cabrio GL (2000-02)
VW Cabrio GLS (1998-02)
VW Cabrio GLX (2001-02)
VW Golf GL (1998-05)
VW Golf GLS (1999-05)
VW Golf GTI (1998-00)
VW Golf K2 (1998)
VW Jetta GL (1998-05)
VW Jetta GLS (1998-05)
VW Jetta GT (1998)
VW Jetta K2 (1998)
VW Jetta Wolfsburg (1998-99)
VW Passat GL (2004)
VW Passat GL TDI (2004-05)
VW Passat GLS (2004-05)
VW Passat GLS TDI (2004-05)

Parts Required:

Rear main seal

Hot Tip:

Be sure to coat the bottom edge of the seal flange with RTV.

Performance Gain:

No more oil leaks

Complementary Modification:

Install lightened flywheel

The rear main seal is an item that should be replaced whenever you replace the clutch. It is one of those while you're in there items that can sometimes come back to bite you if you DON'T replace it. The seal keeps oil from leaking past the crankshaft. Over time, heat and wear will only make the leak worse.

Replacing the seal requires you to remove the transmission clutch, and flywheel from the car. See our articles on Clutch Replacement, Flywheel Replacement and Transmission Removal for more information.

Shown here is a new rear main seal for the VW AVH 2.
Figure 1

Shown here is a new rear main seal for the VW AVH 2.0 engine. The seal is somewhat unique as it is incorporated into a flange that must be replaced as well. In this article, I'll go over the steps involved with replacing the seal yourself.

Loosen and remove the two 5mm hex bolts (green arrows) along the back edge of the oil pan.
Figure 2

Loosen and remove the two 5mm hex bolts (green arrows) along the back edge of the oil pan.

Now loosen and remove the six 5mm hex bolts (green arrows) holding the flange to the engine block.
Figure 3

Now loosen and remove the six 5mm hex bolts (green arrows) holding the flange to the engine block. Once they are removed, carefully pry the flange off the engine.

The new flange installs in place of the old one.
Figure 4

The new flange installs in place of the old one. Be sure to clean the flange mating area (green arrow) with cleaner and a razor blade. You want the surface as clean as possible. Also, don't forget to apply a small amount of silicone RTV sealant to the upper edge of the oil pan (yellow arrow).

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