Volkswagen Workshop Service and Repair Manuals

Removing Perform the following steps: –  Raise floor covering in luggage compartment. Depending on vehicle equipment: –  Remove emergency wheel or tool box for breakdown set.

–  Remove rubber plugs -arrows- from luggage compartment floor. –  Loosen both bolts and pull out. These bolts must later be renewed. –  Raise vehicle.

–  Disconnect exhaust system at clamp -arrows- and remove rear part of exhaust system → Rep. gr.26. –  Set front exhaust pipe with clamp on cross member. –  Unbolt left and right drive shafts from flange shafts of the rear final drive. –  Remove anti-roll bar → Running gear, axles, steering; Rep. gr.42. To prevent damage to the rear left vehicle level sender -G76-:

–  Separate connector, unbolt sender and set on suspension link -A-.

–  Unscrew bolts -1- and -2- of pendulum support.

–  Loosen bolts -1- of propshaft intermediate bearing about 2 turns. To prevent later noise due to imbalance:

–  Check if there are coloured marks on flexible coupling and on propshaft flange of rear final drive -arrows-. If not, mark positions of flexible coupling and propshaft flange of rear final drive relative to each other -arrows-. –  Support final drive with engine and gearbox jack -V.A.G 1383 A-.

–  Remove bolt -arrow- from front bonded rubber mounting. This bolt must later be renewed.

–  Remove plate -C- from top of bonded rubber mounting.

–  Press engine and gearbox forwards by hand and secure in this position with an appropriate piece of wood -A-.

–  Unbolt propshaft from rear final drive -arrows-.

–  Counterhold at rear final drive with counterhold -T10172- when loosening propshaft. –  Push final drive as far back as possible. –  Pull propshaft off final drive and rest on cross member, first laying a cloth on the cross member to protect the shaft.

–  Remove left drive shaft -B- from flange and carefully lower.

–  Remove right drive shaft -B- from flange and carefully lower.

–  Separate connector -A- on all-wheel drive control unit -J492-. –  Pull breather lines -arrows- off final drive. Remove final drive   Note With the help of a second mechanic, the final drive is removed by hand. The »first mechanic« holds the final drive securely in the area of the propshaft flange. The »second mechanic« then pushes the engine and gearbox jack -V.A.G 1383 A- to the rear completely from under the vehicle. Then both mechanics remove final drive.

–  First decide »who is doing what«.