Volkswagen Workshop Service and Repair Manuals

Removing and installing rear flexible coupling

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

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

Removing   Note t  A twin pillar lifting platform should be used when working on the propshaft. 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. t  Keep propshaft straight; store and transport fully extended only.

–  Disconnect exhaust system at clamp -arrows- and remove rear part of exhaust system → Rep. gr.26.

–  Loosen bolts -arrows- of propshaft intermediate bearing about 2 turns.

–  Check if there is a coloured mark (paint) on flexible coupling and on flange of Haldex coupling -arrows-. –  If not, mark the positions for the flexible coupling and the flange of the Haldex coupling relative to each other -arrows-.

–  Unbolt rear propshaft tube with flexible coupling and vibration damper from final drive -arrows-. –  Carefully pull rear propshaft tube off centring pin of propshaft flange of final drive.   Note

t  Do not cant propshaft during removal; pull horizontally off centring pin. Seal in centring sleeve -arrow- must not be damaged. t  Flexible coupling and vibration damper cannot be separated from one another.

–  Support propshaft. –  Secure propshaft using belt from gearbox support -V.A.G 1359/2- to prevent it falling down. –  Mark positions of rear flexible coupling and flange of rear propshaft tube relative to each other. –  Unbolt flexible coupling from propshaft tube -arrows-. Installing Install in the reverse order of removal, observing the following:   Note

t  Do not damage seals -arrow- in propshaft flanges during removal and installation. t  Renew propshaft if damaged. t  Do not cant rear propshaft tube; push horizontally onto centring pin. t  All parts of propshaft which have been marked relative to each other must be reinstalled in the same positions. t  Torque settings → Chapter.

Installation position, flexible coupling with vibration damper: t  Collar on outer circumference -arrows- faces away from propshaft tube. t  Three projecting sleeves each propshaft flange of rear final and propshaft flange engage in flexible coupling mounting holes.

–  Attach propshaft to propshaft flange of rear final drive so that marks -arrows- align. Installing intermediate bearing free of tension → Anchor. –  Install exhaust system and align free of tension → Rep. gr.26.   Note t  If droning noises occur during travel, note the following:

t  Remove balancing nut and balancing washer -arrows-. t  Then, if necessary, unbolt propshaft with flexible coupling from propshaft flange of rear final drive and offset it by one hole. t  If droning noises are still audible, front propshaft must be rotated one more hole.