Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ → V.A.G 1383 A Gearbox jack

Removing

Notes:

• ◆ Always renew self-locking nuts.
• ◆ Always renew corroded bolts/nuts.
• ◆ Rear axle tightening torque:

=> Running gear; Repair group 42; Assembly overview rear axle, vehicles with four wheel drive

• ‒ Observe safety precautions .
• ‒ Observe safety precautions => Page 20-3 .
• ‒ With ignition switched off disconnect battery earth strap.
• ‒ Drain fuel tank.

Note:

If necessary the anti-theft coding for the radio must be obtained first.

• ‒ Loosen both rear wheel securing bolts.

• ‒ Remove cap, retaining ring and rubber cup from fuel filler neck.
• ‒ Remove cover in luggage boot floor.
• ‒ → Pull connector and supply and return pipes off flange.

• ‒ → Unclip ABS sensor wire connectors (if fitted) from retainers under rear seat -arrows- and guide the rubber grommets through the floor plate.

Note:

Makes it possible to lower the rear axle.

• ‒ → Unhook handbrake cable -arrows A- from retainers.
• ‒ Unhook exhaust system -arrows B- from axle beam.
• ‒ Unclip brake pipes -arrow C- from the retainer.
• ‒ Disconnect propshaft -1- from the viscous coupling -2- flexible joint (first mark fitting position).

• ‒ → Pull vent pipe -1- out of wiring loom insulation tubing.
• ‒ Pull connector off the positioning element.

• ‒ → Place engine and gearbox jack V.A.G 1383A under final drive.
• ‒ Remove securing bolts -arrows- from final drive mounting bracket on cross member -1-.

• ‒ → Disconnect wishbone from shock absorber -arrow-.

• ‒ → Remove bolts -A- and -B-.

• ‒ → Lower rear axle with engine and gearbox jack V.A.G 1383A
  and separate propshaft from the viscous coupling with a lever.

Note:

When lowering ensure that the viscous coupling centralizing nut -arrow- in the propshaft is not canted and that the oil seal in the propshaft is not damaged.

When lowering set the angle of the engine and gearbox jack plate -2- so that the rear of the final drive lowers first.

• ‒ → Remove filler neck securing bolts -1- .
• ‒ Pull hoses off from vent pipe -2- to activated charcoal filter, return pipe -3- from gravity valve and vent pipe -4- to vent valve of filler neck.
• ‒ Remove fuel tank securing straps.
• ‒ Remove fuel tank heat shield, first remove rear silencer mounting.
• ‒ Remove cross-brace under fuel tank.

Note:

When removing the cross-brace the fuel tank must be supported.

• ‒ Take out fuel tank downwards.

Installing

Installation is done in the reverse sequence.