Drive Shaft, Removing and Installing

Drive shaft, removing and installing

Special tools, testers and auxiliary equipment required

Assembly tool 3139:

Pressing lever 80-200:

^ Bolt M8 x 30 (2x)

Special tools, testers and auxiliary items required

Engine/transmission jack V.A.G 1383 A with universal transmission mounting V.A.G 1359/2:

Removing
- See notes
- Remove rear section of exhaust system as from clamp(s).





- Use press lever - RMV outside mirror 80-200 to pry off rear attachments -A- of heat shield for drive shaft.
- Remove securing bolts -B- for center bearing.

Note: When removing the securing bolts support the drive shaft by hand. Do not bend drive shaft.

- Remove heat shield. Continue supporting drive shaft.
- Screw in securing bolts for center bearing again hand-tight.





- Remove heat shield for drive shaft off transmission -arrows-.





- Check for a factory marking (colored dot) on drive shaft and on drive shaft flange on final drive at the rear. If no colored dot is present, mark the position of the drive shaft flange -arrow A- relative to the rear final drive -arrow B- with a colored dot.





- Engage alignment fixture-4W dr. shaft 3139 and tighten plastic nuts.

Note: Never install assembly appliance onto balance plates.





- Remove securing bolts -arrows- for the center bearing.





- Screw in bolt -3- M10 x 100 into rear final drive.
- To loosen bolts -1- of the rear and front drive shaft, counterhold with an assembly lever -2-.
- Remove securing bolts at the front constant velocity joint, detach the drive shaft and support it using engine/transmission jack V.A.G 1383 A.
- Remove securing bolts at rear constant velocity joint and detach drive shaft.

Note: Only transport and store drive shaft when extended.

Installing
Installation is carried out in reverse order. Note the following:





Note:
^ To avoid imbalance, the flanges of the drive shaft -arrow A- and of the rear final drive -arrow B- must be installed so that the factory color markings or the markings made subsequently are in line.
^ If a new drive shaft is installed and if the factory color marking on the flange of the rear final drive is no longer visible, the radial run-out on the drive shaft flange must be measured and the color marking on the drive shaft placed in line with the new marking on the flange.
^ Replace gaskets on flange shafts (detach protective foil and stick gasket onto flange shaft).
^ Remove the old and dry high-temperature grease from the constant velocity joints and the flanges for the drive shaft. Replace with the exact same quantity of new high-temperature grease G 000 633.
^ Note the installation position of the drive shaft: The central constant velocity joint is located behind the center bearing facing toward the rear final drive.
^ After removing the drive shaft from the rear final drive, a thick washer that may be located between the shim and the bolt head must not be reinstalled.
^ It is essential that the locking fluid remaining in the threads in the flange shafts on the transmission and rear final drive is cleaned out after removing the drive shaft. Otherwise there is a danger that the new bolts will seize when they are screwed in and then shear if they have to removed later.
^ The threaded holes can be cleaned with a thread tap.
^ Replace drive shaft bolts (self-locking).

- Install drive shaft and attach bolts for constant velocity joint.





- Screw in securing bolts -arrows- for center bearing hand-tight.





- Screw in bolt -3- M10 x 100 into rear final drive.
- To tighten bolts -1- of the rear and front drive shaft, counterhold with an assembly lever -2-.





- Remove assembly device 3139
- Remove securing bolts -arrows- for the center bearing. The drive shaft must be supported manually by a second mechanic.

Note: When removing the securing bolts support the drive shaft by hand.





- Install heat shield -2-. Continue supporting drive shaft.
- Screw in securing bolts -4- for left and right center bearing several turns.
- Secure heat shield -2- on right and left at the center bearing -3- using bolts -1- (M8x30).

Note: When tightening the combination bolt -4- make sure that the center plug -arrow A- is located at the securing bore -arrow B-.





- Tighten securing bolts -2- for the center bearing.
- Install rear securing clips for the heat shield.
- Remove bolts -1-
- Install exhaust system and align stress-free:

Tightening torques: