Volkswagen Workshop Service and Repair Manuals

Removing and installing bonded rubber bush

Special tools and workshop equipment required

t	Thrust piece -3416/1-

t	Thrust piece -3416/2-

t	Assembly tool -T10205-

t	Assembly tool -T10254-

t	Assembly tool -T10263-

t	Torque wrench -V.A.G 1332-

t	Engine and gearbox jack -V.A.G 1383 A- with universal gearbox support -V.A.G 1359/2-

t	Brake pedal depressor -V.A.G 1869/2-

t	Hydraulic press -VAS 6178-

t	Foot pump -VAS 6179-

Removing –  Release handbrake. –  Apply brake pedal depressor -V.A.G 1869/2-. –  Raise vehicle to working height. –  Remove wheels. –  Pull connector off speed sensor.

–  Unclip wire -1- for speed sensor from brackets -arrows-.

–  Unscrew bolts for wheel housing liners -arrows- on both sides.

Vehicles with dynamic headlight range control –  Unscrew coupling rod of rear left vehicle level sender -G76- from rear axle -arrow-. Continuation for all vehicles

–  Disconnect left brake line -arrow A- and remove clip -arrow B-. –  Pull left brake hose -1- out of retainer.

–  Unscrew bolt -arrow- and remove retainer -1- from mounting bracket.

–  Disconnect right brake line -arrow A- and remove clip -arrow B-. –  Pull right brake hose -1- out of axle body.

–  Remove handbrake cables from retainers -arrows-. –  Position engine and gearbox jack -V.A.G 1383 A-. –  Secure rear axle with a strap or similar when lowering and removing. –  Unscrew bolts -1- for right and left axle bodies. –  Lower rear axle with engine and gearbox jack -V.A.G 1383 A-.

–  Set up special tools as shown in figure. 1 -  Spindle -T10254/5- 2 -  Nut -T10254/4- 3 -  Thrust piece -3416/2- 4 -  Bonded rubber bush 5 -  Tube -T10263/6- 6 -  Thrust plate -T10205/1- 7 -  Foot pump -VAS 6179- 8 -  Hydraulic press -VAS 6178- and thrust piece -T10205/13- 9 -  Nut -T10254/4- –  Take up play in special tools.

–  Tube -T10263/6--1- must be positioned on bonded rubber bush so that outer diameter is able to rest evenly on axle body -arrow-. –  Pull out bonded rubber bush by actuating pump.   Note The outer ring of the bush shears off when the bonded rubber bush is pulled out. This occurs with a loud bang.

–  The bonded rubber bush must be removed from the tube -T10356/6- once the bush has been pulled out. –  Clamp tube -T10356/6- on the intended surfaces in a vice. –  Insert a screwdriver between tube -T10356/6- and bonded rubber bush and lever bush out of tube -arrow-. If necessary, apply a drift to bush and drive out with light hammer blows. Installing

–  Bolt new bonded rubber bush with specified special tools. 1 -  Spindle -T10254/5- 2 -  Nut -T10254/4- 3 -  Thrust piece -3416/1- 4 -  Bonded rubber bush 5 -  Thrust piece -3416/2- 6 -  Nut M12 x 1.5, commercially available Face end of bonded rubber bush is equipped with a lug, which fits precisely into recess on thrust piece -3416/2--5-. –  Mark position of lug on long side of bonded rubber bush -arrow-.

–  Now bring bonded rubber bush with special tools into position on rear axle. 1 -  Spindle -T10254/5- 2 -  Nut -T10254/4- 3 -  Hydraulic press -VAS 6178- and thrust piece -T10205/13- 4 -  Foot pump -VAS 6179- 5 -  Thrust plate -T10205/1- 6 -  Tube -T10263/6- 7 -  Bonded rubber bush 8 -  Thrust piece -3416/1- 9 -  Nut -T10254/4-

–  Before pressing in bonded rubber bush, make sure that previously made marking aligns with edge -arrow- of axle body. –  Press in the bonded rubber bush. –  Check position of bonded rubber bush after installing. –  Grease the kidney-shaped cavities on the bonded rubber bush with assembly paste -G 052 150 A2- before installing rear axle. Noises can occur when the vehicle is driven if the rear axle is installed “dry”. –  Tighten rear axle in unladen position → Chapter. Continue installation in reverse order. –  Bleed brake system → Brake systems; Rep. Gr.47. –  Install wheels and tighten bolts or nuts → Chapter.

Specified torques

Component	Specified torque
Rear axle to mounting bracket t  Use new bolts and nuts. t  Tighten bolts and nuts in unladen position.	45 Nm + 90°
Rear left vehicle level sender -G76- to axle body	15 Nm
Retainer for left brake line	20 Nm
Brake lines to brake hose	14 Nm