Rear
Removing
- Remove wheels.
- Disconnect connector behind Three Way Catalytic Converter (TWC) and remove rear part of exhaust system.
- Secure propshaft using a wire -arrows- or similar, otherwise the constant velocity joint can be damaged.
It is essential that the installation position is marked -arrows- before the propshaft is removed. Offset installation will cause excessive imbalance.
- Unbolt propshaft from rear final drive.
- Pull out securing clip -1- and unhook parking brake cable from brake caliper.
Note: Do not damage parking brake boot when removing and installing.
- Loosen bolt -A- on both sides.
- Unhook parking brake cables -B- out of retainer -C-.
- Press locking lugs -A- together and push parking brake cables -2- out from control arm -1-.
Note: Do not pull on parking brake cable otherwise the parking brake adjustment will be changed!
- Remove securing bolts -arrows- from brake caliper housing while counterholding on guide pins.
- Take off brake caliper housing and secure with wire so that the weight of the brake caliper does not stress or damage the brake hose.
- Unbolt vehicle speed sensor wiring -2-.
1. Securing pin
- Unclip vehicle speed sensor wiring from axle beam.
3. Securing point to axle beam
- Disconnect ABS vehicle speed sensor from wheel bearing housing.
Vehicles with automatic headlight range control
- Remove nut -arrow A- from coupling rod -1- for vehicle attitude sensor -2- while counterholding on wrench surfaces -arrow B-.
- Pull coupling rod -1- in direction of arrow out of vehicle attitude sensor-2-.
3. Upper control arm
Continued for all vehicles
- Remove control arm from shock absorber.
1. Control arm
2. Parking brake cable
3. Shock absorber bolt
A- Parking brake cable retaining clip
- Place transmission jack e.g. VAG 1383 A under final drive.
- Remove axle beam bolts.
- Lower rear axle using transmission jack e.g. VAG 1383 A.
Installing
Install in reverse order.
- Install wheel and tighten.
Notes:
^ After subframe, align as described from
^ After installing check parking brake cable adjustment and adjust if necessary!
Tightening torques:
Subframe to body
Shock absorber to control arm
Brake caliper to brake carrier
- Propshaft to rear final drive
Aligning subframe to vehicle
Aligning subframe transversely
- Determine distance between subframe and longitudinal member.
Gap -a- must be same on left and right-hand sides.
Aligning subframe longitudinally
- Measure dimension -a-.
Dimension -a-: 418 ± 2 mm
Tighten bolts for subframe.
After installing check position of steering wheel during a test drive.
If steering wheel is not in straight ahead position, the front axle tracking must be checked!
Bonded rubber mountings for subframe, replacing
Special tools, workshop equipment, test and measuring appliances and aux. items required
^ VW 402 Thrust plate
^ 3291 Assembly tool
^ 3346 Assembly tool
^ 3354 Assembly tool
The bonded rubber mountings can only be removed and installed with the subframe lowered.
Removing and installing subframe
Except for the anti-roll bar, no other parts need be removed from the subframe.
Marking installation position of bonded rubber mounting on subframe
Mark installation position of defective bonded rubber mounting before removing so that the new bonded rubber mounting can be installed in the correct position.
- Pry aluminum washer off bonded rubber mounting with a screwdriver.
- Mark position of semicircle cut-out-arrow on subframe with, for example a felt tip pen.
Pulling out bonded rubber mounting
- Install tools as shown in illustration.
- Pull out bonded rubber mounting by tightening the spindle.
Pulling in bonded rubber mounting
Front and rear bonded rubber mountings differ.
Make sure correct allocation when installing.
1. Bonded rubber mounting
- Insert the bonded rubber mounting so that the cut-out -arrow- faces the marking -1-.
The eccentric hole -B- in bonded rubber mounting must point forward -arrow A-.
- Now put bonded rubber mounting and special tool into position.
Note: Use lubricant to press in the bonded rubber mounting e.g. lubricant G 294 421 A1
CAUTION: Make sure the bonded rubber mounting does not bend when pulling in otherwise the aluminum washer may be damaged!
- Pull in the bonded rubber mounting until the chamfer-arrows- is positioned before the mounting hole.
- Check that the chamfer of the outer ring is positioned evenly. Correct installation position again if necessary.
- Slowly pull bonded rubber mounting completely in.
The tools and the bonded rubber mounting, must be guided by a second mechanic when pulling in.
Installing subframe
The arrows on the bonded rubber mounting aluminum washers must point to rear.
1. Hex bolt
Use new bolts!
2. Aluminum washer for front bonded rubber mounting
3. Aluminum washer for rear bonded rubber mounting
- Tighten bolts for subframe.
Subframe and final drive, overview
1. Subframe
^ Aligning subframe to vehicle
2. Washer
3. Nut, 40 Nm
4. Protective plate
5. Washer
6. Hex bolt M12 x 1.5 x 130
7. Bonded rubber mounting
^ Replacing rubber bonded mounting
8. Hex bolt M 10x 75
9. Hex socket head bolt M10 x 45, 55 Nm
10. Hex socket head bolt M10 x 25, 40 Nm
11. Final drive support
^ Replacing bonded rubber mounting
12. Final drive
^ If the final drive IS removed, the protective plate -item 4 must be removed on some vehicles see fig 1
13. Cross member
^ Replacing bonded rubber mounting
Fig. 1 Removing protective plate
- Remove protective plate -1- from cross member -arrows-, if installed.
The cross member securing bolts remain installed on subframe.
- To remove final drive:
Bonded rubber mounting for cross member in and out, pressing
Special tools, workshop equipment, test and measuring appliances and aux. items required
^ VW401 Thrust plate
^ VW412 Press tool
^ 2039 Tube
^ 3053 Guide sleeve
Fig. 1 Installation position of bonded rubber mounting in cross member
- Mark installation position -arrows- with for example a felt tip pen.
Fig. 2 Pressing bonded rubber mounting out of cross member
Fig. 3 Pulling bonded rubber mounting into cross member
- Position bonded rubber mounting so that one of the rubber nipples -1- on illustration N42-0225 aligns with marking -arrow-.
Bonded rubber mounting for final drive support in and out, pressing
Special tools, workshop equipment, test and measuring appliances and aux. items required
^ VW401 Thrust plate
^ VW412 Press tool
^ 2039 Tube
^ 3053 Guide sleeve
Fig. 1 Mark installation position of bonded rubber mounting
- For example, mark installation position -arrow A- with a felt tip pen.
Fig. 2 Pressing bonded rubber mounting out of transmission support
Fig. 3 Pressing bonded rubber mounting into transmission support
- Position bonded rubber bearing so that one of the rubber nipples aligns with marking -arrow A-.