Audi Workshop Service and Repair Manuals

Servicing propshaft - exploded view of components

Special tools and workshop equipment required

t	Drive flange installing tool -VW 391-

t	Thrust plate -VW 401-

t	Thrust 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	2 - Kukko 18/0 puller

t	3 - Kukko 17/1 splitter

t  Support plate -T10108/1-   Note t  In order to achieve the quietest possible running, only the complete propshaft is balanced during manufacture. The balancing of the complete propshaft or the individual propshaft tubes cannot be carried out with workshop equipment. Therefore, if the front or rear propshaft tube is damaged, always renew the complete propshaft. t  Do not bend propshaft; only store and transport fully extended. t  Before removing, mark the positions of all parts in relation to each other. Reinstall in the same position to avoid excessive imbalance, resulting in bearing damage and rumbling noise. t  Removing and installing propshaft → Chapter

1 -	Manual gearbox with bevel box

2 -	Flange bolt with twelve-point head, 50 Nm and turn 90° further

q	Always renew

3 -	Flexible coupling with heat shield

q	Installation position: open side of heat shield points towards gearbox

q	Removing and installing → Chapter

4 -	Flange bolt with twelve-point head, 60 Nm

5 -	Centring sleeve

6 -	Propshaft tube (front)

q	Do not damage centring sleeve -5- and seal in centre of flange when removing and installing

7 -	Socket head bolt, 40 Nm

q	Always renew

8 -	Lock plate

9 -

Clip

q	Tensioning → Fig.

10 -	Boot for constant velocity joint

q	Drive off with a drift before pressing off CV joint

q	Check for damage

11 -	Dished spring

q	Inner diameter serrated

q	Installation position: large diameter lies against CV joint

12 -

Gasket

q	Renew; pull off backing and stick onto joint

13 -	Constant velocity joint

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Press 25 g G-6.3 grease from each side (in total 50 g) into joint. Regrease joint if necessary when renewing boot

14 -

Circlip

q

Renew

q	Remove and install using circlip pliers -VW 161A-

15 -	Hexagon bolt, 45 Nm

16 -

Washer

q	Always renew

17 -

Flange

18 -	Centre bearing

q	Pulling off → Fig.

q	Installation position → Fig.

q	Driving on → Fig.

19 -	Bolt with washer, 25 Nm

q	Also secures heat shield

20 -	Propshaft tube (rear)

q	Do not damage centring sleeve -5- and seal in centre of flange when removing and installing

q	Clamp in a vice to loosen and tighten bolt connections → Fig.

21 -	Centring sleeve

22 -	Flange bolt with twelve-point head, 60 Nm

23 -	Balancing nut, 10 Nm

q	Not fitted on all propshafts

q	If the flange bolt → Item was loosened, the balancing nut and the balancing washer → Item must NOT be re-installed.

24 -	Balancing washer

q	Only fitted on balanced final drive units

25 -	Flange bolt with hexagon head, 50 Nm and turn 90° further

q	Always renew

26 -	Flexible coupling with vibration damper

q	Installation position → Fig.

27 -	Rear final drive

Pressing off constant velocity joint

Pressing on constant velocity joint –  Press on carefully. –  Tighten tensioner -V.A.G 40-204A-, propshaft must not be pressed down in tensioner, as this causes paint damage. –  If necessary, repair paint damage as follows: remove grease residue with nitro thinner -L 001 600-. Apply 2-component acrylic paint -ALN 769 041- with hardener -ALZ 009 001-.

Tightening clip Refer to → Parts catalogue for clip required in the event of a repair.

Clamp rear propshaft tube into a vice using support plate -T10108/1-. –  Secure support plate -T10108/1- to flexible coupling of propshaft tube. –  To do so, fit nuts -B- onto bolts -A- between support plate -T10108/1- and flexible coupling. A -  Bolt M10 x 70 mm with nut B -  M12 nut

Pulling off flange

Pressing on flange

Pulling off centre bearing –  The rubber guide of the centre bearing must be cut and the metal cover removed. A -  Splitter 12...75 mm, e.g. -Kukko 17/1- B -  Puller, e.g. -Kukko 18/0-

Installation position of centre bearing The longer shoulder -A- points to left -arrow- (as seen in direction of travel).

Driving on centre bearing –  Drive on centre bearing until limit stop.

Installation position of flexible coupling with vibration damper The shoulder on the outer circumference -arrows- must point away from the propshaft tube.