Removing and installing axle beam, four-wheel drive — VW

Removing and installing axle beam, four-wheel drive
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Tensioning strap
T10038
Removing
Raise vehicle and remove rear wheels.
Secure both sides of vehicle to lifting platform using
tensioning straps
T10038
at a suitable point.
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
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
under axle beam.
Secure axle beam with tensioning straps of universal support.
Raise axle beam slightly using
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
.
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
.
If fitted, remove
rear left vehicle level sender
G76
Running gear, axles, steering
Rep. gr.
43
Adaptive suspension; Removing and installing rear vehicle level sender
G76
/
G77
.
Unscrew shock absorber threaded connection from rear axle on both sides
arrow
.
Loosen clamps and pull rear axle breather hoses
arrows
from connections.
Separate electrical connectors
1
and
2
at
all-wheel drive control unit
J492
. Unclip line from axle assembly.
Mark point at which propshaft joins rear axle propshaft flange.
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 rear axle propshaft flange.
Pull propshaft from propshaft flange and guide propshaft centrally upwards.
Using a suitable piece of wood as a support, place propshaft down on tunnel support
1
in this position.
Unscrew nuts
arrows
from leaf spring fastening at spring clamping plates on both sides.
Remove spring clamping plates and U bolts from axle assembly.
Lower axle beam using
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
.
Loosen tensioning strap on universal support.
Lift axle beam off
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
.
Installing
Installation is performed in reverse sequence; note the following:
Note
Only use new securing bolts and securing nuts!
On installation, make sure that leaf spring guide bolt engages in leaf spring mounting bore.
Make sure that marks on flange and shaft align.
Carry out a road test on completion of all assembly work.
Specified torques
Chapter
“
Assembly overview - rear wheel suspension, four-wheel drive
”
Brake system
Rep. gr.
46
Rear brakes; Removing and installing brake pads
Rep. gr.
39
Propshaft; Assembly overview - propshaft