Volkswagen Workshop Service and Repair Manuals

Assembly overview - repairing propshaft

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 -40 - 204 A-

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

t	Torque wrench -V.A.G 1331/-

t	Circlip pliers -VW 161 A-

t	Puller -2 - Kukko 18/0-

t	Splitter -3 - Kukko 17/1-

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.

1 -	Gearbox with bevel box

2 -	12-point flange bolt, 60 Nm

3 -	Flexible coupling with heat shield

q	Removing and installing → Chapter

q	Installation position → Fig.

4 -	12-point flange bolt, 60 Nm

5 -	Front propshaft tube

q	Do not damage centring sleeve or seal inside flange when removing and installing.

6 -	Socket head bolt, 40 Nm

7 -	Locking plate

8 -

Clamp

q	Tightening → Fig.

9 -	Constant velocity joint boot

q	Drive off with a drift before pressing off constant velocity joint

q	Check for damage

10 -	Dished washer

q	Inner circumference serrated.

q	Installation position: Large diameter lies against constant velocity joint.

11 -

Seal

q	Renewing: pull off protective foil and stick onto joint.

12 -	Constant velocity joint

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Filling with grease: press 25 g grease -G6.3- into joint from each side (50 g total). Add grease if necessary when renewing joint boot.

13 -	Retaining ring

q

Renew

q	Remove and install with circlip pliers -VW 161A-.

14 -	Hexagon bolt, 45 Nm

15 -

Washer

q	Always renew

16 -

Flange

q	Pulling off → Fig.

q	Pulling on → Fig.

17 -	Intermediate bearing

q	Pulling off → Fig.

q	Installation position → Fig.

q	Driving on → Fig.

18 -	Bolt, 25 Nm

19 -	Rear propshaft tube

q	Do not damage centring sleeve or seal inside flange when removing and installing.

20 -	12-point flange bolt, 60 Nm

q	Modification: from 06.99, new securing bolts with 12-point socket heads.

q	Two of the new securing bolts might be installed with balancing discs instead of washers.

q	Balancing washers on bolts have been discontinued with introduction of balancing nuts → Item and balancing washers → Item on bolts → Item.

21 -	Balancing nut

q	Not fitted on all propshafts.

q	If flange bolt → Item is loosened, balancing nut and balancing washer → Item must not be reinstalled.

22 -	Balancing washer

q	Not fitted on all propshafts.

q	If flange bolt → Item is loosened, balancing nut and balancing washer → Item must not be reinstalled.

23 -	12-point flange bolt, 60 Nm

q	Modification: From 09.02 onwards, new securing bolts with balancing nuts → Item and balancing washers → Item were introduced for some propshafts

q	Two of the new securing bolts might be installed with a balancing nut and balancing washer.

q	If securing bolts are unscrewed, balancing washer and balancing nut are not allowed to be reinstalled

Balancing washers in conjunction with bolt → Item are not installed then.

24 -	Flexible coupling with vibration damper

q	Removing and installing → Chapter

q	Installation position → Fig.

25 -	Rear final drive

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. –  Repair possible paint damage as follows: remove residual grease or oil with nitro thinner -L 001 600-. Apply 2 component acrylic paint -ALN 769 041- with hardener -ALZ 009 001-.

Tightening clamp Allocate clamps using → Electronic parts catalogue (ETKA).

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-

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.