404119 Removing and installing front drive shaft
WM 404119 Removing and installing front drive shaft
Tools
Technical values
Preliminary work
Preliminary work for removing and installing front drive shaft
1. Remove hub cap using puller hook 9229 and loosen drive shaft mounting at the side of the wheel before raising the vehicle. Also press the brake whilst doing so (second mechanic required). -> 404119 Removing and installing front drive shaft - section on "Removing"
Lock nut on drive shaft (shown as an example)
2. For 19-inch brake system:
Remove air guide. -> 407719 Removing and installing anti-roll bar - section on "Removing" 407719 Removing and installing anti-roll bar
3. Remove connecting link. -> 407819 Removing and installing front connecting link - section on "Removing" 407819 Removing and installing front connecting link
Removing front drive shaft
WARNING
Wheel bearing housing raised incorrectly
- Risk of squashing
- Risk of damage to components
-> Wear personal protective gear.
-> Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
Information
- To prevent damage to the drive shaft, suspension subframe or transmission flange, slide a protective tube (shop-made) 00000 over the drive shaft.
Information
- The pictures shown in this document may differ from the original.
- However, this does not affect the validity and relevance of the pictures.
1. Unscrew fastening screws -1, 2- for holders -3, 4- for brake hydraulic lines.
Holders for hydraulic lines
2. Loosen holder from wheel bearing housing -5-.
3. Release electric plug connections -1- for speed sensor on wheel bearing housing -a- and pull them off -A-.
Plug connections on wheel bearing housing (shown as an example)
4. Remove the brake caliper and suspend it at a suitable position in the wheel arch => Suspending brake caliper (do not open brake hydraulics!).
Also protect the brake caliper (e.g. with a cloth or suitable rubber mat) to prevent damage to the paintwork.
Suspending brake caliper
5. Remove the brake disc. -> 465019 Removing and installing front brake disc - section on "Removing" 465019 Removing and installing front brake disc
6. Use universal drive shaft/wheel hub extractor as of model '86 Nr.87-1 to press out the pin of the drive shaft by max.=> Length: 10 mm+5 mm ( => Pressing out drive shaft, max. 10 mm (shown as an example) ). When doing this, check drive shaft clearance on the halfshaft flange.
Pressing out drive shaft, max. 10 mm (shown as an example)
7. Unscrew the fastening screw -2- for the spring strut -3- and at the same time, raise the axle support -1- as far as required using a suitable jack -4- so that the fastening screw can be unscrewed easily.
Make sure not to damage the brake cover plate.
Removing spring strut mounting
8. Secure the trailing arm -2- at the top with the spring tensioner VW 552 spring tensioner VW 552 -1-.
The spring tensioner is engaged in the top opening of the wheel housing and in the upper trailing arm and is tensioned slightly to avoid damaging the upper ball joint -3-.
Securing upper trailing arm
9. Remove the jack.
10. Remove tie rod from the wheel bearing housing using ball joint puller T10187. -> 487919 Removing and installing tie rod - section on "Removing" Service and Repair
11. Remove upper trailing arm from the wheel bearing housing using ball joint puller T10187. -> 401519 Removing and installing upper trailing arm (steel springs) - section on "Removing" 401519 Removing and installing upper trailing arm (steel springs)
12. Unscrew fastening screws -1- from the drive shaft on the transmission.
Screws securing drive shaft to transmission
13. One mechanic must carefully pull the upper wheel bearing housing out and turn the steering.
The second mechanic must carefully pull out the drive shaft.
14. Secure the wheel bearing housing by fixing it in place in the upper control arm.
Installing front drive shaft
WARNING
Wheel bearing housing raised incorrectly
- Risk of squashing
- Risk of damage to components
-> Wear personal protective gear.
-> Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
Information
- All screws and bolts on the axle must be tightened in vehicle position. Vehicle position means: vehicle resting on its wheels, or the wheel suspension is lifted with a universal jack. -Dimension X- from lower edge of wing to centre of axle corresponds to vehicle position. For the current height values, please refer to the adjustment values for suspension alignment -> 4495TW Adjustment values for suspension alignment 4495TW Adjustment values for suspension alignment.
Dimension -X-: lower edge of wing to centre of axle (shown as an example)
- Visually inspect all parts.
- Replace self-locking nuts.
- Replace all expansion screws (screws fitted using torque angle tightening procedure).
- Use correct tightening torques and torque angle. -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle
Information
- The spring strut screws are under tension. Carefully lever out the lower spring strut connection. Use a suitable lift with a rubber base.
- Make sure not to damage the brake cover plate.
Spring strut support (shown as an example)
Information
- The pictures shown in this document may differ from the original.
- However, this does not affect the validity and relevance of the pictures.
1. Grease the toothing with a little Optimoly TA aluminium paste and fit the drive shaft into the wheel bearing housing. When doing this, press the inner joint together tightly.
One mechanic must carefully pull the upper wheel bearing housing out and turn the steering.
The second mechanic must carefully insert the drive shaft.
Information
- The drive shaft must be pulled in as far as it will go using the fitting tool T10206.
Fitting tool T10206 (shown as an example)
2. Pull the drive shaft into the wheel bearing housing.
3. Fit inner section of drive shaft on the transmission flange.
4. Fit fastening screws -1- for securing drive shaft to transmission. -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle
Screws securing drive shaft to transmission
5. Grease the mounting-face ring of the axle nut with a little Optimoly TA aluminium paste. Fit the axle nuts to prevent the shaft from slipping out.
6. Counter with a screwdriver 9546 when tightening the ball joints if necessary.
7. Fit tie rod on the wheel bearing housing. -> 487919 Removing and installing tie rod - section on "Installing" Service and Repair
8. Fit ball joint of the upper trailing arm on the wheel bearing housing. -> 401519 Removing and installing upper trailing arm (steel springs) - section on "Installing" 401519 Removing and installing upper trailing arm (steel springs)
9. Use a suitable jack -4- to raise the trailing arm and remove spring tensioner VW 552 -1- from the upper trailing arm -2-.
Securing upper trailing arm
10. Raise the axle support -1- as far as required until the fastening screw -2- slides easily through the spring strut -3- and axle support.
Tighten fastening screw. -> 401719 Removing and installing lower trailing arm - section on "Installing" 401719 Removing and installing lower trailing arm
Spring strut threaded joint
11. Fit the brake disc. -> 465019 Removing and installing front brake disc - section on "Installing" 465019 Removing and installing front brake disc
12. Fit the brake caliper. -> 473919 Removing and installing front brake caliper - section on "Installing" 473919 Removing and installing front brake calliper 473919 Removing and installing front brake calliper (PCCB)
13. Plug in electric plug connection -1- for the speed sensor on the wheel bearing housing -A- and lock it -a-.
Electric plug connection for speed sensor (shown as an example)
14. Fit the holders -1, 2- for the hydraulic lines on the wheel bearing housing -3-.
Mounting for hydraulic lines
Subsequent work
Subsequent work for removing and installing front drive shaft
1. Fit connecting link. -> 407819 Removing and installing front connecting link - section on "Installing" 407819 Removing and installing front connecting link
2. For 19-inch brake system:
Fit air guide. -> 407719 Removing and installing anti-roll bar - section on "Installing" 407719 Removing and installing anti-roll bar
3. Fit lock nut for the drive shaft. -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle
4. Fit hub cap.