39881900 Removing and installing four-wheel final drive
WM 398819 Removing and installing four-wheel final drive
Tools
Technical values
Preliminary work for all-wheel final drive
1. Remove right engine compartment cover => 700219 Removing and installing front cover (engine compartment) - section on "Removing".
2. Support the engine. => 1001IN Supporting engine on the body
3. Remove front wheels. => 440519 Removing and installing wheel - section on "Removing"
4. Remove engine guard => 108019 Removing and installing engine guard - section on "Removing".
5. Remove front cardan shaft => 390219 Removing and installing front cardan shaft - section on "Removing".
Information
Tools and materials
The following tools are described in Tools and Equipment, Section 3.0.13 "WE 1206" (exceptions are noted).
Lifting platform
Tool overview
Complete structure of the base carrier with mounting mandrels
Removing all-wheel final drive
Overview of front-axle final drive
1. Clamp steering wheel in centre position with steering wheel holder -figure-.
Steering wheel holder
2. Unscrew plastic nuts -arrows- on front right wheel housing liner.
Wheel housing liner mount
3. Engage special tool spring compressor VW 552 in top of wheel housing, behind wheel housing liner, and support the spring strut.
Installation position of spring compressor
4. Remove cover plate on the steering -arrows-.
Cover plate on steering
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.
Universal joint bolted connection
7. Remove left and right drive shafts from the all-wheel final drive using multiple-tooth socket-wrench insert M12 Nr.31.
8. Undo fastening screws for all-wheel final drive and screw on drive flange.
VAG bolts
Information
- Supports 1, 4 and 7 must be fitted to the unit lifting platform.
9. Raise unit lifting platform until it is touching the front-axle carrier.
Information
- Fastening screw -left arrow- at front right cannot be removed until the front-axle carrier is lowered.
VAG bolts
10. Unscrew bolts -arrows- on front-axle carrier.
Bolts on front-axle carrier
11. Undo bolt connecting spring strut to trailing arm -arrow-.
Bolt connecting spring strut to trailing arm
12. Unscrew servo line holders -arrow- from air-conditioning compressor and remove the line.
Servo line holders
13. Disengage servo line from the front-axle carrier at the three holders -arrows-.
Servo line holders
14. Loosen holders for coolant pipes -arrow- at the body.
Coolant pipe holders
NOTICE
Chassis subframe lowered too far
- Over-extension of joints on the chassis
-> Only lower the chassis subframe sufficiently to allow the transmission to be removed.
15. Lower the front-axle carrier with the unit lifting platform. Remove the vent line from the final drive at the same time.
CAUTION
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.
Information
- A second fitter is required for removing/installing the four-wheel final drive.
16. Press left drive shaft out of flange on final drive.
Pressing out drive shaft
17. Lift transmission and press to the left.
18. Tilt forward the transmission housing together with drive flange.
Movement sequence for all-wheel final drive
19. Remove all-wheel final drive downwards through the front-axle carrier.
Removing all-wheel final drive
Installing all-wheel final drive
Overview of front-axle final drive
CAUTION
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.
Information
- 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.
Installing all-wheel final drive
3. Insert right drive shaft into output flange and place final drive into the mounts on the front-axle carrier.
Movement sequence for installing all-wheel final drive
4. Fit left drive shaft by lifting the final drive output flange.
Fitting left drive shaft
Information
- The front right fastening screw for the four-wheel final drive -left arrow- can only be screwed in with the front-axle carrier lowered.
VAG bolts
5. Insert fastening screws -arrows- for all-wheel final drive and screw for drive flange.
VAG bolts
Information
- Supports 1, 4 and 7 must be fitted to the unit lifting platform.
6. Raise front-axle carrier with unit lifting platform until it is touching the body. Connect vent line at the same time.
Information
- For details of tightening torques for running gear parts, see Group 4 (Running gear) => 40 Tightening torques for front axle.
7. Screw in bolts -arrows- on front-axle carrier.
Bolts on front-axle carrier
8. Screw in bolt -arrow- connecting spring strut to trailing arm.
Bolt connecting spring strut to trailing arm
9. Fit holders -arrow- for coolant pipes to the body.
Coolant pipe holders
10. Engage servo line in the three holders -arrows- on the front-axle carrier.
Servo line holders
11. Screw servo line holders -arrow- on to air-conditioning compressor and clip in the line.
Holder on air-conditioning compressor
Information
- Screws which are tightened with a torque angle must be replaced with new ones.
12. Tighten fastening screw for all-wheel final drive. => Initial tightening: 90 Nm (67 ftlb.) => Final tightening: 90°
Information
- For details of tightening torques for running gear parts, see Group 4 (Running gear) => 40 Tightening torques for front axle.
13. Screw in drive shaft screws.
14. Connect steering column to steering gear. Screw in new screw.
Steering column mounting
15. Install cover plate on the steering.
Cover plate on steering
16. Connect Servotronic plug to the steering gear.
17. Remove special tool spring compressor VW 552 from the spring strut.
Installation position of spring compressor
18. Screw in plastic nuts -arrows- on front right wheel housing liner.
Wheel housing liner mount
19. Remove steering-wheel holder -figure-.
Steering wheel holder
Information
- For details of tightening torques for running gear parts, see Group 4 (Running gear) => 40 Tightening torques for front axle.
20. Tighten bolts -arrows- on front-axle carrier.
Bolts on front-axle carrier
Subsequent work for all-wheel final drive
1. Install front cardan shaft => 390219 Removing and installing front cardan shaft - section on "Installing".
2. Remove engine support. => 1001IN Supporting engine on the body
3. Install right engine compartment cover => 700219 Removing and installing front cover (engine compartment) - section on "Installing".
4. Mount front wheels. => 440519 Removing and installing wheel - section on "Installing"
5. Calibrate steering angle sensor => 456005 Initialising and calibrating steering angle sensor
6. Align front axle and adjust as required. => Suspension alignment complete
7. Install engine guard => 108019 Removing and installing engine guard - section on "Installing".