Front Axle
WM 398819 Removing and installing four-wheel final drive
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 center 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 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.
VAG bolts
Information
- 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.
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
Caution
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.
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 four-wheel final drive
19. Remove four-wheel final drive downwards through the front-axle carrier.
Removing four-wheel final drive
Installing four-wheel final drive
Installing the four-wheel final drive
Overview of front-wheel 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 four-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 four-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 four-wheel final drive and screw for drive flange.
VAG bolts
Information
- 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.
Information
- For details of tightening torques for running gear parts, refer to 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 four-wheel final drive. - Initial tightening: 67 ftlb. - Final tightening: 90°
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 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, refer to Tightening torques for front axle.
20. Tighten bolts -arrows- on front-axle carrier.
Bolts on front-axle carrier
Subsequent work for four-wheel final drive
Subsequent work - final four wheel 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.