Volkswagen Workshop Service and Repair Manuals

Left side –  With vehicle standing on its wheels, loosen left wheel bolts. –  Raise vehicle and remove left wheel.

–  Remove noise insulation tray.

“Newer cars” may have several pieces of noise insulation on the left side.

–  Unbolt pendulum support from subframe.

–  Mark installation position of bolts for swivel joints on left suspension link.

If the bolts are not reinstalled in the same positions during assembly, the alignment must be measured.

–  Remove bolts. –  Unbolt drive shafts from gearbox → Rep. Gr.40.

–  Separate left coupling rod -1- from suspension link and turn coupling rod upwards. –  Swing wheel bearing housing outwards. –  Guide out drive shaft -2- between subframe and gearbox while a 2nd mechanic pushes engine and gearbox forwards. –  The surface protection must not be damaged. Therefore, cable ties are good for securing drive shaft to body. –  Pierce sealing cap in drive flange with a screwdriver and lever out. Vehicles with constant velocity joints

–  To relieve pressure on retaining ring, apply puller -3109- and then remove retaining ring in drive flange.

–  If the drive flange is difficult to move, it can be pulled off using drive flange installing tool -VW 391-. Vehicles with triple-roller joints

–  Here the flange can be pulled off using Kukko -18/0- and two M8x35 bolts. Continuation for all vehicles –  Pull seal out with lever -VW 681-.

–  Half-fill space between sealing lip and dust lip of new seal with grease, e.g. sealing grease -G 052 128 A1-. –  Moisten outer circumference of seal with gear oil.

–  Pull in new oil seal to stop using thrust piece -3319-, M10 threaded rod (approx. 80 mm long) and nut with washer. –  Install drive flange, dished washer and retaining ring.

–  Pull in flange. Flange can also be pulled in using drive flange installing tool -VW 391-. –  Install retaining ring and seal drive flange with new cover. –  Bolt on drive shaft → Rep. Gr.40.

–  Bolt pendulum support to subframe.

–  Install bolts for swivel joint and suspension link on left side in their “old” positions and tighten. –  Attach coupling rod.

If the bolts are not reinstalled in the same positions, the alignment must be measured. For torque specifications for running gear components, see → Rep. Gr.40 –  Check final drive oil level and correct if necessary → Chapter.

–  Install noise insulation tray.