Rear Flexible Disc, Removing

Rear flexible disc, removing





Special tools, testers and auxiliary items required
^ Transmission holder V.A.G 2004
^ Torque wrench V.A.G 1331/
^ Torque wrench V.A.G 1332/
^ Engine/Transmission Jack V.A.G 1383/A
^ Universal transmission support V.A.G 1359/2

Note:
^ Before removing, mark the positions of all parts in relation to each other. Reinstall in identical position otherwise imbalance will be too high which could result in damage to the bearing or in droning noises.
^ Do not kink drive shaft.





^ Sealing ring in drive shaft flange - arrow - must not be damaged during removal and installation.
^ Replace drive shaft if damaged.





A twin pillar vehicle hoist should be used when working on drive shaft.
- Remove center sound insulation - arrows -.





- Remove fuel tank trim - arrows -.





- Remove bracket - 1 - above exhaust system - arrows -.
- Disconnect exhaust system at clamping sleeve - 2 - and remove rear part of exhaust system.





- Remove both catalytic converters on exhaust pipe - arrows -.





- Remove center shield - arrows -.





- Remove flexible disc from rear final drive - arrows -.





- Place Engine/Transmission Jack V.A.G 1383/A with Universal Support V.A.G 1359/2 and a block of wood - 1 - under rear drive shaft tube.





- Remove pendulum support from subframe - arrows A -.





- Remove intermediate bearing for drive shaft from vehicle - arrows -.





- Carefully push engine/transmission toward front and while doing this bring pendulum support in front of subframe to system - arrow _.
- Secure pendulum support with bolt - 1 - (8 x 80 mm) and nut - 2 - to subframe.
- In case of damage to paint, repair as follows: Remove grease residue using nitro-thinner L 001 600. Apply 2-component acrylic paint ALN 769 041 with hardener ALZ 009 001.





- Secure drive shaft against falling down on transmission holder with belt - A -.
- Slide drive shaft tube forward.
- Secure Transmission Holder V.A.G 2004 with bolt - B - and M10 nut to flexible disc.
- When loosening bolt, Transmission Holder V.A.G 2004 is supported on drive shaft tube flange - arrow -.
- Lower drive shaft slightly and remove flexible disc.

Installing
Installation is in reverse order of removal, note the following:





^ Sealing ring in drive shaft flange - arrow - must not be damaged during installation.
^ Replace drive shaft if damaged.
^ Slide rear drive shaft tube on guide pin horizontally.
^ Re-install all parts marked in relation to each other in same location.

Installation position of rear flexible disc
^ Three projecting sleeves each on flange for Haldex clutch and on drive shaft flange grip into mounting holes of flexible discs.





Drive shaft with balancing washers under mounting bolts - arrows -

Note: Any balancing washers present - arrows - must not be installed but rather replaced with washers. See next illustration.





- If balancing washers were installed, they must always be replaced with washers - A -.





Drive shaft with balancing nuts and balancing washers (gradual introduction from 01.03)

Note: Any balancing nuts - A - and balancing washers - B - present must be removed.

Install intermediate bearing without tension.
- Align intermediate bearing on its longitudinal holes so drive shaft is not under stress.
- Only tighten bolts for intermediate bearing to chassis after installing drive shaft.
- Install exhaust system and align free of tension.

Note:
^ If droning noises are audible while driving, do the following:
^ Unbolt drive shaft with flexible disc from flange of Haldex clutch and bolt on again offset by one hole.
^ If droning noises are still heard, drive shaft must be bolted on again, offset by one more hole.

Torque specifications





Pendulum support to subframe (- A - arrows).