Removing and installing front disc coupling — VW

The following description deals with the Audi TT. Therefore differences must be considered, if necessary.

Repairs on the propshaft should be carried out on a two-column vehicle hoist.

Note:

Prior to removal mark the position of all parts in relation to each other. Reinstall in the same positions otherwise the imbalance will be excessive; the bearings could be damaged and humming noises may occur.

Removing

Remove centre noise insulation -arrows-.

Vehicles with 1 charge air cooler:

Separate air hose from turbocharger at air guide tube.

All models:

Where present unscrew mounting for exhaust system from subframe.

Detach exhaust system at clamp -arrows-.
Push clamping sleeve towards the rear.

Unscrew propshaft from disc coupling at angle drive -arrows-.

Note:

Counterhold with a lever on triangle flange when loosening the bolts.

Press front propshaft tube as far as possible towards the rear.

Note:

After loosening the bolts -A- (=>Fig. N34-0887, Page
39-22
) the engine/gearbox mechanical units swing slightly towards to the front. Make sure that the sealing ring -arrow- in the flange of the propshaft is not damaged when removing and installing.

Unscrew pendulum support from subframe -arrows A-.
Carefully press engine/gearbox forward.

Unscrew disc coupling from flange of angle drive -arrows-.

Note:

The disc coupling is shown in illustration with engine removed.

Now carefully remove disc coupling.

Installing

Installation is carried out in the reverse order; note the following:

All parts of the propshaft marked in relation to each other must be installed in the same position.
First insert propshaft bolts into disc coupling then bolt disc coupling to angle drive.

Installation position of front disc coupling

The open side of the heat shield faces the angle drive.
Three protruding sleeves at the disc coupling and the propshaft flange grip into the input bores of the disc couplings.

Notes:

The sealing ring -arrow- in the flange of the propshaft must not be damaged. When sealing ring is damaged propshaft must be replaced.
Slide propshaft horizontally onto the appropriate guide pin.

Stress free alignment of exhaust system

=> 4-cylinder Engine (5-valve turbo), Mechanics; Repair group 26; Removing and installing exhaust system parts; Stress-free alignment of exhaust system
4-cylinder Engine (5-valve turbo), Mechanics
Removing and installing exhaust system parts
Stress-free alignment of exhaust system

Tightening torques

Component · Nm
Bolts -A- for pendulum support · 20 + 90°1)2)
Disc coupling on propshaft · 60
Disc coupling on angle drive · 60

1)
90°corresponds to a quarter turn

2)
Renew bolts