Front Axle
398819 Removing and installing four-wheel final driveTools
Preliminary work for all-wheel final drive
Preliminary work final four wheel drive
1. Remove right engine compartment cover.
2. Support engine.
3. Remove front wheels.
4. Remove engine guard.
5. Remove front cardan shaft.
Removing four-wheel final drive
Overview Of Front-wheel Drive:
1. Clamp steering wheel in centre position with steering wheel holder -figure-.
2. Unscrew plastic nuts -arrows- on front right wheel housing liner.
3. Engage special tool spring compressor VW 552 in top of wheel housing, behind wheel housing liner, and support the spring strut.
4. Remove cover plate on the steering -arrows-.
5. Pull Servotronic plug off the steering gear.
6. Unscrew bolted connection -arrow- securing universal joint to steering gear. Remove universal joint from steering gear.
7. Remove left and right drive shafts from four-wheel final drive using multiple-tooth socket wrench insert M12 NR.31.
8. Undo fastening screws for four-wheel final drive and screw on drive flange.
Note:
^ Supports 1, 2 and 3 must be fitted to the unit lifting platform.
9. Raise unit lifting platform until it bears against the front-axle carrier.
Note:
^ Fastening screw -left arrow- at front right cannot be removed until the front-axle carrier is lowered.
10. Unscrew bolts -arrows- on front-axle carrier.
11. Undo bolt connecting spring strut to trailing arm -arrow-.
12. Unscrew servo line holders -arrow- from air-conditioning compressor and remove the line.
13. Disengage servo line from the front-axle carrier at the three holders-arrows-.
14. Loosen holders for coolant pipes -arrow- at the body.
ATTENTION: Over-extension of drive shafts on running gear!
^ Do not pull front-axle carrier downwards.
15. Lower front-axle carrier with the unit lifting platform. Remove vent line from the final drive at the same time.
ATTENTION: Risk of damage to ATF lines and pressure line for power steering.
^ Protect ATF lines with water hose or similar.
^ The servo line must not be crushed or stretched.
Note:
^ A second fitter is required for removing/installing the four-wheel final drive.
16. Press left drive shaft out of flange on final drive.
17. Lift transmission and press to the left.
18. Tilt forward the transmission housing together with drive flange.
19. Remove four-wheel final drive downwards through the front-axle carrier.
Installing the four-wheel final drive
Overview Of Front-wheel Drive:
ATTENTION: Risk of damage to ATF lines and pressure line for power steering.
^ Protect ATF lines with water hose or similar.
^ The servo line must not be crushed or stretched.
Note:
^ A second fitter is required for removing/installing the four-wheel final drive.
1. Swivel left flange of final drive in over the front-axle carrier.
2. Rotate drive flange upwards and install final drive through the front-axle carrier.
3. Insert right drive shaft into output flange and place final drive into the mounts on the front-axle carrier.
4. Fit left drive shaft by lifting the final drive output flange.
Note:
^ The front right fastening screw for the four-wheel final drive -left arrow- can only be screwed in with the front-axle carrier lowered.
5. Insert fastening screws -arrows- for four-wheel final drive and screw for drive flange.
Note:
^ Supports 1, 2 and 3 must be fitted to the unit lifting platform.
6. Raise front-axle carrier with unit lifting platform until it bears against the body. Position vent line at the same time.
Note:
^ For details of tightening torques for running gear parts, Tightening torques for front axle'.
7. Screw in bolts -arrows- on front-axle carrier.
8. Screw in bolt -arrow- connecting spring strut to trailing arm.
9. Fit holders -arrow- for coolant pipes to the body.
10. Engage servo line in the three holders -arrows- on the front-axle carrier.
11. Screw servo line holders -arrow- onto air-conditioning compressor and clip in the line.
Note:
^ Screws which are tightened with a torque angle must be replaced with new ones.
12. Tighten fastening screw for four-wheel final drive. Initial tightening: 67 ftlb. Final tightening: 90 °
Note:
^ For details of tightening torques for running gear parts, Tightening torques for front axle'.
13. Screw in drive shaft screws.
14. Connect steering column to steering gear. Screw in new screw.
15. Install cover plate on the steering.
16. Connect Servotronic plug to the steering gear.
17. Remove special tool spring compressor VW 552 from spring strut.
18. Screw in plastic nuts -arrows- on front right wheel housing liner.
19. Remove steering-wheel holder -figure-.
Note:
^ For details of tightening torques for running gear parts, Tightening torques for front axle'.
20. Tighten bolts -arrows- on front-axle carrier.
Subsequent work for four-wheel final drive
1. Install front cardan shaft.
2. Remove engine support.
3. Install right engine compartment cover.
4. Mount front wheels.
5. Calibrate steering angle sensor
6. Align front axle and adjust as required.
7. Install engine guard.