Replacement

REMOVAL





- Remove cover (arrows).
- Remove silencer.
- Remove heat shield above front silencer.
- Block rear axle and block wheel.





- If there are no markings, mark position of flange -A- relative to rear final drive -B- with paint.
- Loosen driveshaft mounting screws at rear final drive flanged shaft and at automatic transmission center differential flanged shaft.
- Unbolt driveshaft and tie up.

CAUTION: Tie up driveshaft only far enough as is necessary for removing final drive.





- Unbolt cover plate for left drive shaft (arrows).





- Unbolt differential lock vacuum element holding bracket from rear final drive (arrows).





- Release securing clip -1-.
- Press out vacuum element/selector fork connecting pin -2upward.
- Pull parking brake cable -3- with rubber grommet out of holding bracket.
- Disconnect wiring harness for differential lock switch.
- Detach vacuum hoses from vacuum element-pay attention to colored markings.





- Disconnect right parking brake cable bracket from final drive (arrows).





- Disconnect left and right drive axles and tie up.





- Disconnect parking brake cables at body (arrows).
Detach heat shield for this purpose.
- Support final drive with VAG 1383A.
Insert small support from vehicle jack for this step.





- Rear hanger:
Loosen bolt -a- and unscrew 3 bolts (arrows).





- Loosen bolt (arrow -A-).
- Remove bolt (arrow -B-) and carefully lower crossmember -Ion right side.





- Separate crossmember -I- from crossmember -II- (arrows).
- Separate crossmember -II- from final drive and guide over final drive flange.





- Carefully lower final drive. a - Support from vehicle jack

WARNING: For safety reasons, two persons are required for lowering the final drive, and raising it again for installation.

INSTALLATION
- Installation is the reverse order of removal, noting the following points:





- Before final drive is bolted tight, bracket for right-side parking brake cable must be installed.





- Pay attention to colored markings on vacuum hoses.
Yellow hose to connection -1
Blue hose to connection -2





- When installing driveshaft, make sure that marking point on driveshaft flange -A- and final drive flange -B- are aligned.

NOTE:
^ To ensure that the imbalances of the rear driveshaft flange and rear final drive flange are eliminated, both flanges must be installed in such a way that the markings -A- and -B- are aligned as accurately as possible.
^ No markings are provided in the area of the front driveshaft flange and front final drive.

- Install silencer (muffler).
- Tighten the following to:
Driveshaft to rear final drive: 55 Nm (41 ft lb)

NOTE:
^ Bolts are micro-encapsulated.
^ Always install new bolts.
^ Clean threads in the flanged shafts, re-tap if necessary.

Drive axle to rear final drive:
8 mm bolt: 45 Nm (33 ft lb)
10 mm bolt: 80 Nm (59 ft lb)
Crossmember -I- to body: 45 Nm (33 ft lb)
Crossmember -I- to crossmember -II-: 45 Nm (33 ft lb)
Crossmember -II- to final drive: 45 Nm (33 ft lb)
Vacuum element holding bracket to final drive: 25 Nm (18 ft lb)
Left-side drive axle cover plate to final drive: 25 Nm (18 ft lb)
Right-side parking brake cable bracket to final drive: 25 Nm (18 ft lb)