Servicing propshaft — VW

The servicing propshaft for the New Beetle RSi is fundamentally similar to the Audi TT 1999 ä; 5/6-speed manual gearbox 02MFour-wheel drive/final drives with code letters EUK.

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

Special tools and workshop equipment required

VW 391 Drive shaft assembly device
VW 401 Thrust plate
VW 402 Thrust plate
VW 407 Press tool
VW 408 A Press tool
VW 454 Thrust pad

VW 522 Support sleeve
40-204 A Tensioner
V.A.G 1275 Pliers
V.A.G 1331 Torque wrench
VW 161 A Pliers
2 - Kukko 18/0 Puller
3 - Kukko 17/1 Separating tool

Notes:

In order to achieve the quietest possible only the complete prop shaft is aligned during manufacture. The balancing of the complete prop shaft or the individual prop shaft tubes cannot be carried out with workshop tools. Therefore always replace the complete prop shaft when the front or rear prop shaft is damaged.
Do not bend prop shaft, store and transport extended only.
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.

Manual gearbox with angle drive
Collared screw bolt with hexagon, 60 Nm
Alteration:
As of 06.99 there are new securing bolts with internal hexagon, only for disc coupling on rear final drive.
Up to two of these new securing bolts can be assembled with one balancing plate instead of one packing plate.
After removal of the prop shaft the alignment plates are replaced with serial packing plates => Page
39-9

Disc coupling with heat shield
Installation position => Page
39-23
Removing and installing=>Page
39-19

Prop shaft tube, front
When attaching and removing do not damage the central sleeve and sealing ring in centre of flange =>Page
39-17

Cheese-head bolt, 40 Nm
Shim
Clip
Tensioning => Fig.
3

CV joint boot
Before pressing off inner constant velocity joint drive off with drift
Check for damages

Dished washer
Geared at internal diameter
Installation position: Greater diameter rests on inner constant velocity joint

Gasket
Replace; pull off protective sheet and bond into joint.

Constant velocity joint
Pressing off => Fig.
1
Pressing on => Fig.
2
Grease filling:
Press 25 g G-6.3 grease from each side (in total 50 g) into drive. Regrease joint, if necessary, when replacing the protective boot

Circlip
Replace
Compress in and out with ring pliers VW 161 a

Hexagon bolt, 45 Nm
Washer
Always replace

Flange
Pulling off => Fig.
4
Pulling on =>Fig.
5

Centre support bracket
Pulling off => Fig.
6
Fitting location => Fig.
7
.
Driving on => Fig.
8

Bolt, 25 Nm
Prop shaft tube, rear
When attaching and removing do not damage the central sleeve and sealing ring in centre of flange =>Page
39-17

Disc coupling with oscillation damper
Removing and installing=>Page
39-25

Rear final drive

Fig.1
Pressing off inner constant velocity joint

Fig.2
Pressing on inner constant velocity joint

Carefully press on.
Tighten clamp 40 - 204, prop shaft must not be pressed down in the clamp as this causes paint damage.
If necessary, remove paint damages as follows:
Remove grease residues with nitro thinner L 001 600.
2-Apply component acrylic paint ALN 769 041 with hardener ALZ 009 001.

Fig.3
Tensioning clamp

In case of repair allocate clamp with spare part catalogue.

Fig.4
Pulling off flange

Fig.5
Pulling on flange

Fig.6
Pulling off centre bearing

The rubber guide of the centre bearing must be cut and the metal cover removed.

A - · Separating tool 12...75 mm e.g. Kukko 17/1
B - · Puller, e.g. Kukko 18/0

Fig.7
Installation position of centre bearing

The longer web -A- faces drive direction (arrow) towards the left

Fig.8
Pushing on centre bearing

Drive on centre bearing until limit stop.