Removing and installing axle beam, all wheel drive — VW

Removing and installing axle beam, all wheel drive
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
Tensioning strap
T10038
Removing
Loosen wheel bolts.
Raise vehicle.
Remove rear wheels.
Secure vehicle to hoist at a suitable position using
tensioning straps
T10038
.
WARNING
If the vehicle is not strapped down, there is a danger that the vehicle will slip off the lifting platform during assembly work.
Place
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
under axle beam.
Secure axle beam with tensioning straps of universal support.
Raise axle beam slightly using
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
.
Separate electrical connector of ABS speed sensors on both sides.
Remove rear left and right brake pads
Brake system
Rep. gr.
46
Rear brakes; Removing and installing brake pads
.
Vehicles with vehicle level sender
Unscrew nut
1
.
Pull
rear left vehicle level sender
G76
2
out of bracket
3
.
Continuation for all vehicles
Unscrew shock absorber threaded connection on both sides of rear axle
arrow
.
Loosen clamps and pull off rear axle breather hoses
arrows
from connections.
Separate electrical connectors
1
and
2
at
all wheel drive control unit
J492
. Unclip wire on axle beam.
Mark position of propshaft in relation to propshaft flange on rear axle.
Note
Note that relative positions of all parts must be marked prior to removal. Parts must be reinstalled in the same position, as the imbalance may otherwise be excessive or damage to the bearings or humming noises may otherwise occur.
Unbolt propshaft from propshaft flange of rear axle.
Pull propshaft off propshaft flange, and guide propshaft upwards centrally.
Using a suitable piece of wood as a support, place propshaft down on tunnel support
1
in this position.
Unscrew nuts
arrows
for securing leaf spring to saddle plates on both sides.
Remove saddle plates and U bolts from axle beam.
Lower axle beam using
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
.
Loosen tensioning strap on universal support.
Lift axle beam off
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
.
Installing
Installation is performed in reverse sequence; note the following:
Note
Only use new securing bolts and securing nuts.
Make sure when installing that the leaf spring guide pin engages in the hole in the leaf spring mounting.
Make sure that marks on flange and shaft align.
Perform a road test once all assembly work is complete.
Specified torques
Chapter
“
Assembly overview – axle beam, all wheel drive
”
Brake system
Rep. gr.
46
Rear brakes; Removing and installing brake pads
Propshaft and rear final drive
Rep. gr.
39
Propshaft; Assembly overview - propshaft