Volkswagen Workshop Service and Repair Manuals

I - Assembly overview - rear axle assembly

1 -	Hexagon bolt, 25 Nm

2 -	Inner clamp

3 -	Inner rubber bush

4 -	Anti-roll bar

q	If necessary, repair paint damage and apply corrosion protection coating

5 -	Hexagon bolt, 60 Nm

6 -	Hexagon bolt, 130 Nm

7 -

Support

8 -	Self-locking hexagon nut, 25 Nm

9 -	Outer clamp

10 -	Outer rubber bush

11 -	Bonded rubber bush

q	Removing → Fig.

q	Installing → Fig.

q	Determining installation position → Fig..

q	Premature wear is to be anticipated in the event of non-observance.

12 -	Self-locking hexagon nut, 120 Nm

13 -	Hexagon bolt, 85 Nm

q	12-point hexagon socket head bolt as of vehicle ID No. 1H-SW 320 001 1H-SB 080 001.

14 -	Mounting bracket

q	Do not loosen to remove rear axle.

q	During assembly work, e.g. following accident repairs, contact surfaces must be free of wax and underbody sealant.

15 -	Retainer for handbrake cable

16 -	Final drive

q	Removing and installing, repairing → 5-speed manual gearbox 02C; Rep. Gr.39.

17 -

Washer

18 -	Hexagon bolt, 45 Nm

19 -	Bonded rubber bush

q	Pressing out and in → Fig..

20 -	Hexagon bolt, 75 Nm

21 -	Gearbox mounting

q	Lower rear axle assembly to remove.

22 -	Mounting bracket

23 -	Hexagon bolt, 45 Nm

24 -	Spring washer

q

Renew

25 -	Hexagon bolt, 65 Nm

26 -	Cap nut in longitudinal member for mounting bracket

q	Reworking → Chapter.

27 -	Cross member

q	Remove fuel tank to remove → Rep. Gr.20.

28 -	Cap nut in longitudinal member for mounting bracket

q	Reworking → Chapter.

29 -	Hexagon bolt, 65 Nm

30 -

Axle beam

31 -	Hexagon bolt, 25 Nm

32 -	Spring washer

q

Renew

33 -	Brake pressure regulator

q	Adjusting and setting values → Chapter.

34 -	Hexagon nut, 25 Nm

35 -	Retainer for brake pressure regulator

q	Installation position → Fig..

36 -

Propshaft

q	Removing and installing → 5-speed manual gearbox 02C; Rep. Gr.39.

37 -	Twelve point bolt, 60 Nm

Pressing bonded rubber bush for gearbox mounting in and out Installation depth: flush with lower edge -arrow-.

Installation position of brake pressure regulator retainer Dimension -a- approx. 120 mm

Marking installation position of bonded rubber bush in axle housing –  Mark installation position before removing bonded rubber bush. –  Position straight edge -A- onto bonded rubber bush so that grooves in bore align with straight edge. –  Mark accordingly on axle housing. If installation position has not been marked, proceed as follows → Chapter.

Removing bonded rubber bush from axle housing –  Drive chisel in at several points around circumference between bush and axle housing, and lever bush out. –  Drive out second half of bush from inside using a punch.

Pulling bonded rubber bush into axle housing –  Place one half of bush onto bore in axle housing. Grooves in bush bore must align with mark made on axle housing → Fig.. –  Pull in bush half with fitting tool -3128-.

–  Position second half of bush from below. Grooves on both halves of bush must align. –  Pull in second bush half with fitting tool -3128-.   Note When pulling in, supports -arrow- of fitting tool -3128- must be positioned in pockets -arrow A- of bonded rubber bush.