Removing and Installing

Rear final drive, removing and installing
Special tools and equipment





^ V.A.G 1383 A Engine/transmission hoist with V.A.G 1359/2 transmission support

Removing driveshaft
^ Remove rear part of exhaust system behind clamping sleeve(s):





^ Check whether there is a factory marking (color marking) on drive shaft. If not, mark location of drive shaft flange (arrow -A-) to rear final drive (arrow -B-) with color.
^ Disconnect drive shaft from rear final drive and tie up at exhaust system clamps.





^ Remove heat shields from final drive (arrows).
^ Disconnect left and right drive axles and rest them on suspension links.





^ Remove nuts (arrows) from bonded rubber bushings at rear subframe. The bolts remain inserted.





^ Place VAG 1383A engine/transmission hoist with 1359/2 transmission support under final drive and support final drive.





^ Remove securing bolts (arrows) of left transmission support.
^ Slide bolts through the bonded rubber bushings of rear crossmember.
^ Lower final drive.

Installing drive shaft
Installation is reverse of removal, noting the following:

Note:
^ Always replace self-locking nuts.
^ Always clean any remaining locking fluid from thread for drive flange on rear final drive after driveshaft. Otherwise there is a possibility that the new bolts may get jammed when installed and shear when removed again.
^ Cleaning can be performed with a thread cutter.
^ Replace drive shaft bolts (self-locking).
^ After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and bolt head may not be reinstalled.
^ Replace seals at drive flange (remove protective film and attach gasket to drive flanges).





^ In order to avoid imbalance, the flanges must be installed so that the color markings (arrows) -A- and -B- line up. Installing drive shaft.

^ Top off transmission fluid in rear final drive and check oil level.
^ Install exhaust system free of stress.





Tightening torques

Rear final drive, securing to assembly fixture
Special tools and equipment





^ VW540 Holding fixture





^ Clamp complete rear final drive into VW540 holding fixture.