Removing and Installing All-Wheel Final Drive
Removing and installing all-wheel final drive
Tools
Removing all-wheel final drive
Warning:
A triggering of the airbag (malfunction in the airbag system) caused by improper work on airbag components cannot be ruled out! In the case of such a malfunction, an unsuitable steering wheel holder could cause injury or damage!
^ Use only steering wheel holders that do not project into the area of the airbag unit!
^ Observe safety regulations for airbag vehicles.
1. Clamp steering wheel in centre position with steering wheel holder.
2. Install right engine compartment cover.
3. Support engine.
4. Remove front wheels.
5. Remove engine guard.
6. Remove shield on the steering gear.
7. Unscrew universal joint screw connections to steering gear. Remove universal joint from steering gear.
8. Remove heat shield on the all-wheel final drive.
9. Remove cardan shaft.
10. Remove drive shafts using multiple-tooth socket wrench insert M12 31 on the left and right of the all-wheel final drive.
Note: The front right fastening screw can only be removed by lowering the suspension subframe.
11. Undo all-wheel final drive fastening screws and the screw on the drive flange.
Warning!
Vehicle can fall off the lifting platform!
^ Only raise the unit-elevating platform high enough to ensure that the vehicle does not IN off from the take-up arms of the lifting platform.
Note: Supports 1, 2 and 3 must be mounted on the unit-elevating platform.
12. Lift the unit-elevating platform until it comes into contact with the suspension subframe.
13. Unscrew the suspension subframe screw connections.
14. Unscrew the plastic nuts on the front right wheel housing liner.
15. Engage special tool spring tensioner VW 552 in the top wheel well, behind the wheel housing liner and support the spring strut.
16. Unscrew spring strut screw connections on the axle strut.
Vehicles with Servotronic:
^ Pull off Servotronic plug on the steering gear.
17. Undo servo line on the air-conditioning compressor.
18. Disengage servo line on the suspension subframe on three holders.
19. Lower suspension subframe using the unit-elevating platform. Pull off the vent line on the final drive when doing this.
20. Undo coolant pipe holder on the body.
Note:
^ A second fitter is required in order to remove the final all-wheel drive.
Caution: ATF lines and pressure pipe for power-assisted steering can be damaged when removing the transmission!
^ Protect ATF lines, e.g. with the remaining piece of the water hose or something similar.
^ The servo line must not be crushed or stretched.
21. Push left drive shaft out of the flange on the final drive.
22. Lift transmission and push it to the left.
23. Tilt transmission housing and drive flange forward.
Caution: Joints overstretched on running gear!
^ Do not pull suspension subframe in a downward direction.
24. Remove all-wheel final drive in a downward direction, through the suspension subframe.
Installing final all-wheel drive
Note:
^ A second fitter is required in order to install the all-wheel final drive.
^ During the installation, make sure that the connection for the vent line does not remain hanging on the engine carrier and breaks off.
1. Swivel in the left flange of the final drive over the suspension subframe.
2. Turn the drive flange upward and install the final drive through the suspension subframe.
3. Insert right drive shaft in output flange and place the final drive in the take-up points on the suspension subframe.
4. Insert left drive shaft by lifting the final drive output flange.
Note: The front right fastening screw for the all-wheel final drive can only be screwed in once the suspension subframe has been lowered.
5. Position all-wheel final drive fastening screws and the screw on the drive flange.
6. Screw in spring strut screw connections on the axle strut.
7. Remove special tool spring tensioner VW 552 on the spring strut.
8. Screw in the plastic nuts on the front right wheel housing liner.
Warning:
Vehicle can fall off the lifting platform!
^ Only raise the unit-elevating platform high enough to ensure that the vehicle does not lift off from the take-up arms of the lifting platform.
Note: Supports 1, 2 and 3 must be mounted on the unit-elevating platform.
9. Lift suspension subframe with the unit-elevating platform until it is in contact with the body. Position vent line at the same time.
10. Screw in the suspension subframe screw connections.
11. Engage servo line in the three holders on the suspension subframe.
12. Install water pipe holder on the body.
13. Fasten servo line holder on the air-conditioning compressor.
Vehicles with Servotronic
^ Connect Servotronic plug on the steering gear.
Note:
^ Screws that are tightened to a torque angle must be replaced with new ones.
14. Tighten fastening screw for all-wheel final drive.
Tightening torque: 90 Nm (67 ft. lbs.) + 90° torque angle
15. Screw in screws for drive shaft.
Note:
^ You will find the tightening torques for running gear components in Group 4 (Running gear).
16. Connect steering columns on steering gear. Screw in new screw.
17. Remove heat shield on the steering gear.
Note: The colored markings, match points, on the cardan shaft and on the flange of the rear final drive must be installed along a straight line. This neutralizes the residual imbalance in the components.
18. Install cardan shaft.
19. Install heat shield on all-wheel final drive.
20. Install engine guard.
21. Remove special tool safety device 10-222 A.
22. Remove special tool transport eyebolt 9700.
23. Attach torque converter support on engine side.
Tightening torque: 60 Nm (44 ft. lbs.)
24. Install engine cover for cylinders 5 to 8.
25. Install right engine compartment cover.
26. Fit wheels.
27. Remove steering wheel holder.
28. Calibrate steering angle sensor.
Tightening torques
Note