W/Manual Transmission

Fig. 5 Exploded View Of Rear Axle Assembly:

Refer to Fig. 5 during replacement procedures.
1. Remove rear wheels, then the main/rear muffler system.
2. Remove heat shields, above muffler system and in front of and behind crossmember I.
3. Remove fuel tank cover, then disconnect parking brake cable at crossmember.
4. Remove exhaust system support, then scribe propeller shaft and differential flange for alignment during reassembly.
5. Remove propeller shaft to differential flange attaching bolts, then disconnect propeller shaft, raise up and tie into position with wire. Position propeller shaft only high enough for clearance to remove axle, to prevent damage to universal joint.
6. Remove left axle shaft cover plate, then remove right and left axle shaft to differential flange attaching bolts. Disconnect axle shafts and tie out of way with wire.
7. Disconnect right and left parking brake cable brackets from axle.
8. Disconnect right and left parking brake cables from brake calipers.
9. Disconnect right and left brake lines at caliper hose and brake line junction, then brake line from brake distributor valve on left side.
10. Remove axle mounting nut using a 15 mm socket, then support crossmember using transmission jack VAG 1383/A or equivalent.
11. Remove mounting nuts from rear crossmember, then brackets for parking brake cables.
12. Loosen lefthand bolt at crossmember I, then remove righthand bolt, and carefully lower crossmember I on righthand side.
13. Reposition parking brake cables, routing them toward front, through eyes in crossmember II.
14. Support axle with transmission jack and adapter Nos. VAG 1383/A and VAG 1359/2 or their equivalents. Strap axle securely to jack.
15. Disconnect crossmember I from crossmember II, then the axle from rear crossmember and carefully lower.
16. Reverse procedure to install, noting the following:
a. Propeller shaft and differential flanges must be installed so that scribe marks are aligned.
b. Align four bolts for crossmember I, as centrally as possible in crossmember bolt holes.
c. Prior to installing exhaust system and heat shields, adjust propeller shaft, refer to Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Adjustments.
d. Align exhaust system so that parts are free of tension, prior to tightening.
e. Bleed brake system.
f. Inspect transmission oil in axle and refill as necessary.
g. Tighten nuts and bolts to specifications.