Removing and installing rear axle - Golf syncro, Jetta syncro, Rally Golf — VW

VW
Golf
1984
Jetta
1984
Running gear
Running gear
Edition
11.2005
Removing and installing rear axle - Golf syncro, Jetta syncro, Rally Golf
Note
It is recommended that the axle and differential are removed together and separated away from the vehicle when removing and installing the rear axle. If only the axle beam requires removing then the suspension link may remain on the shock absorbers. Before lowering assembly, disconnect/pull off vacuum lines and electrical wiring in both cases.
Always renew self-locking nuts.
Always renew corroded nuts and bolts.
Coil spring strut
Removing and installing
Fig.
and
Fig.
Dismantling and assembling
Chapter
.
Coil spring allocation
Chapter
.
Drive shaft
Removing and installing
Fig.
and
Fig.
Repairing
Chapter
.
Final drive
Unbolting and bolting on axle beam
Fig.
.
Bearing bracket and gearbox carrier
Unbolting and bolting
Fig.
.
Renewing bonded rubber bush
Fig.
Propshaft
Removing and installing
Fig.
Mark installation position before removing.
Anti-roll bar
Removing and installing
Fig.
Rear axle beam
Removing bonded rubber bush
Fig.
.
Determining installation position
Fig.
.
Installing bonded rubber bush
Fig.
.
Mounting bracket for rear axle
Removing and installing
Fig.
Suspension link
Removing and installing
Fig.
Renewing bonded rubber bush
Fig.
and
Fig.
.
Bonded rubber bush with eccentric bush
Fig.
.
Renewing wheel bearing
Chapter
.
Brake carrier
Removing and installing
Fig.
Removing and installing anti-roll bar
Unbolting and bolting suspension link from/to axle housing
Move suspension link to horizontal position before tightening (unladen state).
Unbolting and bolting suspension strut/shock absorber from/to suspension link
Move suspension link to horizontal position before securing (unladen state). Unbolting and bolting suspension strut to body
Fig.
.
Unbolting and bolting axle housing from/to body
If mounting brackets on body are released, axle must be aligned on wheel alignment unit following re-installation.
Unbolting and bolting mounting bracket from/to gearbox carrier
Remove and install together.
When assembling mounting bracket and gearbox carrier away for vehicle ensure parts are installed and aligned correctly. Bonded rubber bushes must be installed in vehicle so that they are not stressed.
Unbolting and bolting propshaft and drive shaft from/to differential.
Before unbolting propshaft, mark installation position. Excessive imbalance will occur if the installation position is not correct.
Caution
Suspend propshaft with binding wire. Subsequent damage otherwise occurs on CV joint.
Unbolting and bolting on drive shaft
Caution
Loosen and tighten only when vehicle is standing on its wheels (danger of accident).
Unbolting and bolting final drive to axle beam
Unbolting and bolting on viscous coupling
5-speed manual gearbox 009, four-wheel drive
Rep. Gr.
39
Final drive; Rear differential
.
Unbolting and bolting brake carrier
First remove wheel hub
Fig.
.
Pulling out bonded rubber bush
A
Socket insert, 17 mm
B
Splitter, 12 … 75 mm, e.g.
Kukko 17/1
Pulling in bonded rubber bush
First coat rubber with
assembly paste
G 052 109 A2
.
Installation position: bush shoulder outwards on outer bush and bush shoulder inwards on inner bush (towards centre of vehicle).
Note
On rear axle camber and toe can be corrected with a bonded rubber bush with eccentric bush
Fig.
.
Bonded rubber bush with eccentric bush
When installing bush with eccentric bush, note the following:
Eccentricity upwards = negative camber change
Eccentricity downwards = positive camber change
Eccentricity forwards = positive toe change
Eccentricity backwards = negative toe change
Camber or toe corrections up to 18 ′ are possible with this bush.
Note
This bonded rubber bush may only be used on the inner mounting of the suspension link.
Pressing bonded rubber bush for gearbox carrier in and out
Installation position: Arbitrary
Wheel offset depth: Flush
Removing bonded rubber bush
Note
Mark installation position before removing.
Drive chisel in at several points around circumference between bush and axle housing, and lever bush out.
Drive out second half of bush from inside using a punch.
Determining installation position
If installation position has not been marked, proceed as follows:
1. Determining vehicle longitudinal axis on axle housing
Place a straight edge or similar on both bush bores (vertical dot-dash line in illustration) and scribe a line on axle housing eye through imaginary centre point of bore.
2. Installing one bush half under 40° angle
Place
protractor
3084
onto bore and then mark 40° position.
Position bush accordingly and pull in with
fitting tool
3128
.
When positioning second bush half, ensure that grooves in both bush halves align
arrows
.
Pull in second bush half.
Installing bonded rubber bush
Position one half of the bonded rubber bush correctly and pull in with
fitting tool
3128
. Then position second half of bush and pull in.