Removing and Installing Four-Wheel Final Drive
Removing and installing four-wheel final driveTools
Preliminary work for all-wheel final drive
1. Remove right engine compartment cover.
2. Support engine.
3. Remove front wheels.
4. Remove engine guard
5. Remove front cardan shaft.
Removing four-wheel final drive
Overview of front-wheel drive
Steering wheel holder
1. Clamp steering wheel in centre position with steering wheel holder -figure-.
Wheel housing liner mount
2. Unscrew plastic nuts -arrows- on front right wheel housing liner.
Installation position of spring compressor
3. Engage special tool spring compressor VW 552 in top of wheel housing, behind wheel housing liner, and support the springstrut.
Cover plate on steering
4. Remove cover plate on the steering -arrows-.
5. Pull Servotronic plug off the steering gear.
Universal joint bolted connection
6. Unscrew bolted connection -arrow- securing universal joint to steering gear. Remove universal joint from steering gear.
7. Remove left and right drive shafts from four-wheel final drive using multiple-tooth socket wrench insert M12 NR.31.
VAG bolts
8. Undo fastening screws for four-wheel final drive and screw on drive flange.
Note: Supports 1, 2 and 3 must be fitted to the unit lifting platform.
9. Raise unit lifting platform until it bears against the front-axle carrier.
VAG bolts
Note: Fastening screw -left arrow- at front right cannot be removed until the front-axle carrier is lowered.
Bolts on front-axle carrier
10. Unscrew bolts -arrows- on front-axle carrier.
Bolt connecting spring strut to trailing arm
11. Undo bolt connecting spring strut to trailing arm -arrow-.
Servo line holders
12. Unscrew servo line holders -arrow- from air-conditioning compressor and remove the line.
Servo line holders
13. Disengage servo line from the front-axle carrier at the three holders -arrows-.
vent line from the final drive at the same time.
14. Loosen holders for coolant pipes -arrow- at the body. Coolant pipe holders
ATTENTION: Over-extension of drive shafts on running gear!
-> Do not pull front-axle carrier downwards.
15. Lower front-axle carrier with the unit lifting platform. Remove
four-wheel final drive.
ATTENTION: Risk of damage to ATF lines and pressure line for power steering. ->
-> Protect ATF lines with water hose or similar.
-> The servo line must not be crushed or stretched.
Note: A second fitter is required for removing/installing the
16. Press left drive shaft out of flange on final drive. Pressing out drive shaft
17. Lift transmission and press to the left.
Movement sequence for four-wheel final drive
18. Tilt forward the transmission housing together with drive flange.
Removing four-wheel final drive
19. Remove four-wheel final drive downwards through the front-axle carrier.
Installing the four-wheel final drive
Overview of front-wheel drive
ATTENTION: Risk of damage to ATF lines and pressure line for power steering.
-> Protect ATF lines with water hose or similar.
-> The servo line must not be crushed or stretched.
Note: A second fitter is required for removing/installing the four-wheel final drive.
1. Swivel left flange of final drive in over the front-axle carrier.
Installing four-wheel final drive
2. Rotate drive flange upwards and install final drive through the front-axle carrier.
Movement sequence for installing four-wheel final drive
3. Insert right drive shaft into output flange and place final drive into the mounts on the front-axle carrier.
Fitting left drive shaft
4. Fit left drive shaft by lifting the final drive output flange.
VAG bolts
Note: The front right fastening screw for the four-wheel final drive -left arrow- can only be screwed in with the front-axle carrier lowered.
VAG bolts
5. Insert fastening screws -arrows- for four-wheel final drive and screw for drive flange.
Note: Supports 1, 2 and 3 must be fitted to the unit lifting platform.
6. Raise front-axle carrier with unit lifting platform until it bears against the body. Position vent line at the same time.
Bolts on front-axle carrier
Note: For details of tightening torques for running gear parts, see Tightening torques for front axle'.
7. Screw in bolts -arrows- on front-axle carrier.
Bolt connecting spring strut to trailing arm
8. Screw in bolt -arrow- connecting spring strut to trailing arm.
Coolant pipe holders
9. Fit holders -arrow- for coolant pipes to the body.
Servo line holders
10. Engage servo line in the three holders -arrows- on the front-axle carrier.
Holder on air-conditioning compressor
11. Screw servo line holders -arrow- on to air-conditioning compressor and clip in the line.
Note: Screws which are tightened with a torque angle must be replaced with new ones.
12. Tighten fastening screw for four-wheel final drive. Initial tightening 67 ft. lbs. Final tightening 90°
Note: For details of tightening torques for running gear parts, see Tightening torques for front axle'.
13. Screw in drive shaft screws.
Steering column mounting
14. Connect steering column to steering gear. Screw in new screw.
Cover plate on steering
15. Install cover plate on the steering.
16. Connect Servotronic plug to the steering gear.
Installation position of spring compressor
17. Remove special tool spring compressor VW 552 from spring strut.
Wheel housing liner mount
18. Screw in plastic nuts -arrows- on front right wheel housing liner.
Steering wheel holder
19. Remove steering-wheel holder -figure-.
Bolts on front-axle carrier
Note: For details of tightening torques for running gear parts, see Tightening torques for front axle'.
20. Tighten bolts -arrows- on front-axle carrier.
Subsequent work for four-wheel final drive
1. Install front cardan shaft.
2. Remove engine support.
3. Install right engine compartment cover.
4. Mount front wheels.
5. Calibrate steering angle sensor
6. Align front axle and adjust as required.
7. Install engine guard.