Front Final Drive
Front Final Drive
Special tools, testers and auxiliary items required
• Engine support bridge (10-222 A)
• Spindle (10-222 A/10)
• Supports (10-222 A/19)
• Engine Sling (2024 A) with Bracket (2024 A/1)
• Engine/transmission jack (V.A.G 1383 A)
• Bracket (T10014)
• Counterhold tool (T10172) with adapters (T10172/6)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
Removing
- On vehicles with air suspension, activate vehicle lifting mode.
- Remove left and right front wheel housing liners.
Vehicles with 4.2L FSI engine:
- Remove left and right air filter housing.
Vehicles with TDI engine:
- Remove air filter housing.
All:
- Remove both front wheels.
- Remove screws and remove front - 1 - and rear - 2 - noise insulation.
- Remove noise insulation bracket - arrows -.
- Remove left and right coupling rods from stabilizer bar - arrow -.
- If equipped, remove right heat shield from front final drive - arrows -.
- Check whether there is a factory marking (colored marking) on front driveshaft and at driveshaft flange. If not, identify position of driveshaft CV joint - arrow A - to driveshaft flange at front final drive - arrow B - with paint.
- Remove bolts - 1 - at front final drive/front driveshaft connection.
- Use counterhold tool (T10172) with the adapters (T10172/6) to do this.
- Slide front driveshaft together with transfer case; CV joints can be moved axially.
- Remove drive axle from front final drive.
- Disconnect electrical connector - arrow - at steering gear.
- Remove heat shield - A - from steering gear.
• Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
• Do not change steering wheel position and steering gear position any more.
- Remove universal joint bolt - B -.
- Press universal joint off of steering gear.
Vehicles with TDI engine:
- Remove hydraulic line bracket bolt - 1 -.
- Remove hydraulic lines - 2 - from steering gear.
Vehicles with 4.2L FSI engine:
- Disengage power steering hydraulic line from bracket at left of engine.
All:
- Remove nuts and bolts on refrigerant lines retaining clamp - arrows -.
• When connections are loosened, coolant lines may be moved aside slightly to position the Supports (10-222 A/19) on the longmembers.
Vehicles with 4.2L FSI engine:
- Remove rear engine cover - arrows -.
- Remove front engine cover - arrows -.
- Position Engine Support Bridge (10-222 A) with Adapters (10-222 A/22) and Connectors (T40091/3) on bolted fender flanges.
- Install additional Engine Support Bridge (10-222 A) parts as illustrated. Position Supports (10-222 A/19) on notches in longmembers.
- Engage hooks on both short Spindles (10-222 A/10) at engine lifting eyes.
- Slide Support (T40091/2) with both Slides (T40093/5) into both Supports (T40093/4).
- Install long spindles from Engine Support Bridge (10-222 A) and engage spindle hooks at both front engine lifting eyes.
Secure Support (T40091/2) with Connector (T40093/4) pins and splints.
- Raise engine slightly by tensioning all spindles evenly in order to achieve even weight distribution.
Vehicles with 3.0L TDI engine:
- Carefully pull engine cover - arrows - off 4 retaining pins one after the other.
• Before removing ribbed belt, identify running direction with chalk or felt-tip pen. Reversed running direction on a used ribbed belt can lead to destruction.
- To release tension from ribbed belt, swing tensioner in direction of - arrow -. Use a lever with TORX 60 socket to do this.
- Remove ribbed belt from tensioning roller.
- Remove bolts - arrows - and remove ribbed belt tensioner.
- Install Engine Support (T10014) in ribbed belt tensioner securing holes.
- Position Engine Support Bridge (10-222 A) with Connectors (T40091/3) and 2 spindles on bolted fender flanges.
• Spindles are at front.
- Engage both spindles at both engine rear lifting eyes.
- Install additional Engine Support Bridge (10-222 A) parts as illustrated. Position Supports (10-222 A/19) on notches in longmembers.
- Slide Support (T40091/2) with Slide (T40093/5) into both Connectors (T40093/4).
Secure Support (T40091/2) with Connector (T40093/4) pins and splints.
- Remove Engine Sling (2024 A) eyes.
- Re-insert bolts - 1 - in middle engine sling hole and secure with a spring clip.
- Engage engine sling pins in front engine support bridge spindle.
- Install Bracket (2024 A/1) at left side of engine sling.
- Engage Engine Sling (2024 A) at right front engine lifting eye and at Engine Support (T10014).
Mounting hooks and connecting pins on engine sling must be secured with plug connectors - arrows -.
- Raise engine slightly by tensioning all spindles evenly in order to achieve even weight distribution.
All:
- Position Engine/Transmission Jack (V.A.G 1383 A) at bottom of subframe and lay wooden support - A - under subframe and wooden support - B - under front final drive.
Transmission bracket bolts - 1 - and engine bracket bolts - 3 - must not be removed for the following steps.
To avoid axle alignment later, subframe must be secured with Locating Pins (T10300).
- Secure subframe with Locating Pins (T10300).
- With subframe supported, remove bolts - 4 -.
- Lower subframe with front final drive by dimension - a - using Engine/Transmission Jack (V.A.G 1383 A).
• Dimension - a - = 200 mm.
• If necessary, pull subframe down slightly.
- Remove threaded connections - 1 to 3 - for front final drive - A -/subframe - B -.
• A 2nd technician is needed to remove the front final drive.
Remove front final drive - 1 - toward rear as follows between subframe and engine/transmission assembly:
- Put left driveshaft up.
- Have 2nd technician remove front final drive from mounts in subframe while guiding right driveshaft out of flange shaft.
- Raise front final drive over steering gear and guide it back and out.
Installing
Install in reverse order, paying attention to the following:
• A 2nd technician is needed to insert front final drive in subframe mounts.
- Install threaded connections - 1 to 3 - for front final drive - A -/subframe - B -.
- Install subframe.
- Attach front driveshaft to front final drive. Refer to => [ Front Driveshaft ] Front Driveshaft.
- If equipped, fasten right heat shield to front final drive with locking fluid (D 154 100 A1) - arrows -.
- Install universal joint on steering gear.
- Install hydraulic lines at steering gear.
- Attach coupling rods to stabilizer at left and right.
Vehicles with 3.0L TDI engine:
- Install ribbed belt tensioner.
All:
- On vehicles with air suspension, deactivate the lift mode.
Tightening Specifications
• The torque specifications apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.
• Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
• Do not use degreased parts.
• Tolerance for torque specification ± 15%.
