Volkswagen Workshop Service and Repair Manuals

Repairing propshaft   Note t  To obtain the quietest possible running, the entire propshaft is balanced during manufacture. It is not possible to balance the entire propshaft or separate propshaft tubes with workshop equipment. Therefore, in the event of damage to the front or rear propshaft tube, the entire propshaft must always be renewed. t  Keep propshaft straight; store and transport fully extended only. 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  Removing and installing propshaft → Chapter.

Special tools and workshop equipment required

t	Drive shaft fitting appliance -VW 391-

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408A-

t	Drift sleeve -VW 244B-

t	Support sleeve -VW 522-

t	Tensioner -V.A.G 40-204A-

t	Hose clip pliers -V.A.G 1275-

t	Torque wrench -V.A.G 1331-

t	Circlip pliers -VW 161A-

t	Puller -2 - Kukko 18/0-

t	Splitter -3 - Kukko 17/1-

t  Thrust plate -40 - 105-

t  Two arm puller -1 Kukko 20/10-

t  Support plate -T10108/1-

Pressing off constant velocity joint

Pressing on constant velocity joint –  Press on carefully. –  Tighten tensioner -40 - 204 A- securely. Propshaft must not be pushed down within tensioner -40 - 204 A-, or paintwork will be damaged. –  Any damage to paintwork must be repaired according to the guidelines in → Paint workshop manual.

Tightening clamp

Clamping rear propshaft tube in a vice using stop plate -T10108/1- –  Secure stop plate -T10108/1- on flexible coupling of propshaft tube. –  Place nuts -B- between stop plate -T10108/1- and flexible coupling onto bolts -A-. A -  Bolt M10 x 70 mm with nut B -  Nut M12

Pulling off flange

Pulling on flange

Pulling off intermediate bearing –  Rubber guide of intermediate bearing must be cut through and metal casing removed. A -  Splitter, 12...75 mm, e.g. -Kukko 17/1- B -  Puller, e.g. -Kukko 18/0- –  Tighten splitter-A- with flat side of wedges behind intermediate bearing. –  Then attach two arm puller-B- to splitter. –  Pull intermediate bearing off propshaft tube. A -  Splitter, 12...75 mm, e.g. -Kukko 17/1- B -  Two arm puller, e.g. -Kukko 20/10-

Installation position of intermediate bearing The longer support -A- faces to left in direction of travel -arrow-.

Driving on intermediate bearing –  Drive on intermediate bearing to stop.

Installation position of flexible coupling with vibration damper Collar on outer circumference -arrows- faces away from propshaft tube.