Volkswagen Workshop Service and Repair Manuals

Removing and installing propshaft Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Torque wrench -V.A.G 1332- Additional required information t  Workshop Manual Golf 1998 ►, Bora 1999 ► Engine, mechanics t  Workshop Manual Golf 1998 ►, Bora 1999 ►, Running gear, axles, steering - front and four-wheel drive A twin pillar lifting platform should be used when working on the propshaft.   Note t  Before removing, mark positions of all parts relative to each other. Reinstall in the same position otherwise imbalance will be excessive, the mountings could be damaged causing rumbling noises. t  Keep propshaft straight; store and transport fully extended only. Removing

–  Remove retainer -1- above exhaust system -arrows-. –  Separate exhaust system at double clamp -2- and remove with catalytic converter (2nd mechanic). –  Remove rear part of exhaust system → Rep. Gr.26. –  Now remove rear and front heat shield.

–  Unbolt front propshaft tube with flexible coupling from bevel box flange -arrows-.

–  Remove pendulum support from subframe -arrows A-.

–  Separate front propshaft from rear propshaft -arrows-. –  Carefully press engine and gearbox forwards. –  Carefully pull front propshaft off centring pin.   Note

When removing and installing do not damage seals in propshaft flanges. –  Swing front propshaft down and remove.

–  Unbolt rear propshaft with flexible coupling and vibration damper from rear final drive -arrows-. –  Unbolt propshaft intermediate bearing from vehicle. –  Carefully pull rear propshaft off centring pin.   Note t  Flexible coupling and vibration damper cannot be separated from one another.

t  Do not cant propshaft during removal; pull horizontally off centring pin. Centring sleeve seal must not be damaged -arrow-; otherwise the complete propshaft must be renewed. Installing Install in the reverse order of removal, observing the following:   Note

t  Do not damage seals in propshaft flanges -arrow- during removal and installation. t  Renew propshaft if damaged. t  Do not cant front or rear propshaft tube; push horizontally onto respective centring pin.

Installation position for rear flexible coupling t  Three projecting sleeves each on Haldex coupling flange and propshaft flange engage in mounting holes of flexible coupling. –  Attach propshaft to Haldex coupling flange so that markings -arrows- align.

From 06.99, new balancing discs and new securing bolts between propshaft and Haldex coupling flange have been used -arrows-. The new securing bolts have 12-point socket heads.

Two of the new securing bolts might be installed with one balancing disc each. –  Balancing discs must always be replaced with washers -A-. Allocation of washers → ETKA (Electronic parts catalogue)

From 09.02 onwards: Securing bolts with balancing nuts and balancing washers for propshaft on flexible coupling -arrows-. Balancing washers -A- (⇒ previous Fig.) are discontinued in that case. Installing intermediate bearing free of tension. –  Align intermediate bearing in its elongated holes so that propshaft is not under tension. –  Do not tighten intermediate bearing bolts to body until after propshaft has been installed.   Note t  If droning noises occur during travel, note the following: t  Unbolt propshaft with flexible coupling from Haldex coupling flange and offset it by one hole. t  If droning noises are still audible, front propshaft must be rotated one more hole. Specified torques

Pendulum support on subframe -arrows A- → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40. Intermediate bearing to body → Item. Flexible coupling with damper to Haldex coupling flange → Item. Flexible joint with heat shield to bevel box flange → Item Connecting bolts to constant velocity joint → Item. Flexible coupling with heat shield to propshaft → Item Flexible coupling with vibration damper to propshaft → Item